Usability features for respiratory humidification system

ABSTRACT

A humidification system for delivering humidified gases to a user can include a heater base, humidification chamber having an inlet, outlet, and associated fluid conduit, and breathing circuit including a supply conduit, inspiratory conduit, and optional expiratory conduit. The humidification system can include various features to help make set-up less difficult and time-consuming. For example, the supply conduit, inspiratory conduit, and optional expiratory conduit can be coupled into a one-piece circuit to aid set-up. Various components can be color-coded and can have corresponding structures to indicate which components should be connected to one another during set-up. Such features can also help make the set-up process more intuitive for an operator, which can reduce the need for specialized training and reduce the number of potential errors.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority benefit of U.S. Provisional ApplicationNo. 61/992,442, filed May 13, 2014, U.S. Provisional Application No.62/032,208, filed Aug. 1, 2014, and U.S. Provisional Application No.62/127,443, filed Mar. 3, 2015, each of which is hereby incorporated byreference herein. The following provisional applications are herebyincorporated by reference in their entirety: U.S. ProvisionalApplication No. 61/919,485, filed Dec. 20, 2013; U.S. ProvisionalApplication No. 61/893,758, filed Oct. 21, 2013; U.S. ProvisionalApplication No. 61/877,566, filed Sep. 13, 2013; U.S. ProvisionalApplication No. 61/877,784, filed Sep. 13, 2013; U.S. ProvisionalApplication No. 62/024,969, filed Jul. 15, 2014; and U.S. ProvisionalApplication No. 62/032,462, filed Aug. 1, 2014.

BACKGROUND

Field of the Disclosure

The present disclosure generally relates to humidification systems forhumidifying gases supplied to users, and more particularly, tohumidification systems having features for improved assembly andusability.

Description of the Related Art

Many gas humidification systems deliver heated and humidified gases forvarious medical procedures, including respiratory treatment,laparoscopy, and the like. These systems can be configured to controltemperature, humidity, and flow rates through the use of varioussensors.

Various components of such systems also can include features designed tohelp control the system and/or help provide users with gases havingdesired characteristics. Such gas humidification systems can includemany components that must be assembled prior to use. The set-up processcan be complicated and time-consuming, and may require specializedtraining. The specialized training may need to be repeated for each newemployee or user. Thus, there is a need for a system that is intuitiveto assemble and use without extensive training.

Circuits for use in medical systems often comprise a cap to aid withstorage and to protect against ingress of dust or contaminants. However,prior art caps comprise materials that may cause damage to an internalsurface of the circuit. Caps can fall off in storage or leak. Caps canbe challenging for a user to insert and to remove, requiring high forcesto insert and/or remove.

Caps often remain connected with the circuit as a user sets up themedical system. For example, in a respiratory system, the cap remainsconnected with the circuit until the patient interface is connected tothe circuit. A user may activate a gases source while the cap remains inplace on the circuit. As a result, pressure building up in the circuitcan cause the cap to fail. Failure is measured, for example, by the capcoming off the circuit, or by damage to circuit components caused bypressure increases.

Circuits are often bulky and difficult to manipulate in use. A usersetting up the system in advance may attempt to drape the circuit acrossother components in the system in an effort to keep the circuit frombeing contaminated, for example, by touching the floor. The circuit canbe prone to falling to the floor and becoming contaminated.

SUMMARY

A humidification system for delivering humidified gases to a user cancomprise a heater base, a humidification chamber having an inlet,outlet, and associated liquid conduit, and a breathing circuit includinga supply conduit, inspiratory conduit, and optional expiratory conduit.A humidification system can comprise various features as describedherein to help make set-up less difficult and time-consuming. Suchfeatures can also help make the set-up process more intuitive for anoperator, which can reduce the need for specialized training and reducethe number of potential errors.

According to some aspects of the present disclosure, a humidificationapparatus comprises a humidification chamber configured to hold a volumeof liquid. The humidification chamber comprises at least one side wall,a top wall connected to the at least one side wall, a cavity at leastpartially defined by the at least one side wall and the top wall, aninlet port defining a passage into the cavity of the humidificationchamber, an outlet port defining a passage out of the cavity of thehumidification chamber and having an elbow configuration, wherein theoutlet port is uncovered for shipping and/or storage, and a port capconfigured to cover the inlet port for shipping and/or storage, the portcap comprising a leg that extends into the inlet port.

The inlet port can comprise a baffle extending at least partially belowthe inlet port and configured to inhibit splashing through the inletport, wherein the leg of the port cap is configured to extend below thebaffle. The leg of the port cap can be configured to secure one or morefloats within the humidification chamber for shipping and/or storage.The chamber can further comprise a liquid inlet in fluid communicationwith the cavity and a liquid conduit having a first end coupled to theliquid inlet and a second end coupled to a spike configured to beconnected to a liquid source, wherein the spike is positioned under theport cap for shipping and/or storage. The liquid conduit can be loopedand inserted under the port cap during assembly for shipping and/orstorage. The chamber can further comprise a liquid inlet in fluidcommunication with the cavity and a liquid conduit having a first endcoupled to the liquid inlet and a second end coupled to a spikeconfigured to be connected to a liquid source, wherein the spike isstored in a sheath attached to the port cap for shipping and/or storage.

The chamber can further comprise a handle coupled to the chamber, ashelf extending between a portion of the handle and a portion of the atleast one side wall of the chamber, a liquid inlet in fluidcommunication with the cavity, and a liquid conduit having a first endcoupled to the liquid inlet and a second end coupled to a spikeconfigured to be connected to a liquid source, wherein the spike isstored on the shelf for shipping and/or storage. The liquid conduit canbe stored on the shelf for shipping and/or storage. The port cap cancomprise a ring configured to be grasped for removal of the port cap andto be attached to a medical stand. The humidification apparatus canfurther comprise an inspiratory conduit having a first end coupled tothe outlet port for shipping and/or storage. The port cap can comprise acontact surface, and a heater base configured to support thehumidification chamber can comprise a lifting surface, so that when thehumidification chamber is inserted onto the heater base with the portcap covering the inlet port, the lifting surface contacts the contactsurface and causes the port cap to lift away from the inlet port. Thelifting surface can be on a sensor cartridge module coupled to theheater base.

According to some aspects of the present disclosure, a circuit end capcomprises a body configured to be inserted into an end of a breathingcircuit component, a flange at a first end of the body, wherein adiameter of the flange is larger than a diameter of the body and a lowersurface of the flange configured to face the body is configured to sealagainst the end of the breathing circuit component, and a pull ringextending from the body and configured to be used to aid removal of thecircuit end cap from the breathing circuit component and/or to hang thebreathing circuit component from a medical stand or hook.

The body can comprise frustoconical tapers configured to form a sealinginterface with an interior of the breathing circuit component. The bodycan comprise three frustoconical tapers such that the frustoconicaltapers provide a sufficient friction fit with the breathing circuitcomponent while allowing the circuit end cap to be removed from thebreathing circuit component without excessive force. The pull ring canextend from a top surface of the flange along a longitudinal axis of thebody. Alternatively, the pull ring can extend from a side of the flangeperpendicularly to a longitudinal axis of the body. A diameter of theflange can be selected for use with various breathing circuitcomponents. The diameter of the body and frustoconical tapers can beselected for use with various breathing circuit components. The body cancomprise a plurality of channels, each channel extending parallel to alongitudinal axis of the body on an outside surface of the body, whereinthe channels allow gases to vent from the breathing circuit component.The plurality of channels can extend into the lower surface of theflange. The body can comprises a plurality of channels extendingparallel to a longitudinal axis of the body on an outside surface of thebody, wherein the channels separate the frustoconical tapers into aplurality of segments.

According to some aspects of the present disclosure, a humidificationchamber is packaged with the inlet port and the outlet port covered by aport cap. The port cap can be designed to help indicate to the operatorthat the port cap should be removed and discarded during set-up. Aliquid conduit, or feedset, can be contained and concealed by the portcap so that the feedset cannot be connected to a liquid source until theport cap is removed. The port cap can be designed to cover only theinlet port or only the outlet port.

According to some aspects of the present disclosure, a supply conduit,an inspiratory conduit, and an optional expiratory conduit are coupledinto a one-piece assembly to aid set-up. The conduits can be coupled by,for example, a mesh sheath, clips, or any other appropriate couplingmechanism. One or more of the conduits can be removably coupled to theothers. The expiratory conduit can include an electrical plug configuredto be connected to a socket on the heater base to power a heatingelement within the conduit. One or more of the conduits can includeintegrated sensors and adaptor cables to connect the sensors to theheater base.

According to some aspects of the present disclosure, various componentsof a humidification system are color-coded and can have correspondingstructures to indicate which components should be connected to oneanother during set-up. The heater base and/or consumables packaging canalso include a schematic or step-by-step instructions to help guide theoperator through the set-up procedure.

According to some aspects of the present disclosure, a humidificationapparatus comprises a heater base and a humidification chamber. Theheater base comprises a heater and a display, the heater plate beingconfigured to support a humidification chamber and the display orientedat an angle of about 22° from vertical. The humidification chamber canbe configured to hold a volume of liquid and can comprise at least oneside wall, a top wall connected to the at least one side wall, a basesurface connected to the at least one side wall, a cavity being at leastpartially defined by the at least one side wall and the top wall, atleast one of the at least one side wall and the top wall of thehumidification chamber having features that define a front of thehumidification chamber and a back of the humidification chamber, aliquid inlet in fluid communication with the cavity, the liquid inletpositioned closer to the front of the humidification chamber than theback of the humidification chamber, an inlet port defining a passageinto the cavity of the humidification chamber, an outlet port defining apassage out of the cavity of the humidification chamber, wherein theoutlet port has an elbow shape, and a liquid conduit having a first endcoupled to the liquid inlet and a second end configured to be connectedto a liquid source. The liquid conduit can comprise a first end coupledto the liquid inlet and a second end coupled to a spike configured to beconnected to a liquid source.

According to some aspects of the present disclosure, a humidificationapparatus comprises a heater base, a humidification chamber, and aliquid conduit. The heater base comprises first and second sensors and aheater plate, the first and second sensors being positioned verticallyhigher than the heater plate, the heater plate being configured tosupport a humidification chamber. The humidification chamber can beconfigured to hold a volume of liquid and can comprise at least one sidewall, a top wall connected to the at least one side wall, a cavity beingat least partially defined by the at least one side wall and the topwall, a liquid inlet in fluid communication with the cavity, an inletport extending through the top wall and defining a passage into thecavity, the inlet port having an aperture configured to receive thefirst sensor, an outlet port extending through the top wall and defininga passage out of the cavity, the outlet port having an apertureconfigured to receive the second sensor, and interlock features in thetop wall configured to receive corresponding interlock features on theheater base to guide insertion of the chamber on the heater base so thatthe first and second sensors are received in the apertures of the inletand outlet ports. The first and second sensors can be integrated into asensor cartridge module that is mechanically and electrically connectedto the heater base.

The humidification apparatus can further comprise a supply conduit andan inspiratory conduit, wherein a first end of the supply conduitcomprises a chamber end connector configured to be coupled to the inletport, a second end of the supply conduit is configured to be coupled toa gases supply, at least part of the inlet port comprises a firstindicator, at least part of the supply conduit chamber end connectorcomprises the first indicator, a first end of the inspiratory conduitcomprises a chamber end connector configured to be coupled to the outletport, at least part of the outlet port comprises a second indicator, andat least part of the inspiratory conduit chamber end connector comprisesthe second indicator. The first indicator can comprise a first color,and the second indicator can comprise a second color.

The interlock features in the top wall can comprise a recess and theinterlock features on the heater base can comprise a protrusion, therecess configured to receive the protrusion, and the protrusionconfigured to extend greater than halfway across the chamber when thechamber is fully installed on the heater base. The interlock features inthe top wall can further comprise a raised portion and the interlockfeatures on the heater base can further comprise a central channellocated on a bottom surface of the protrusion, the raised portionconfigured to be received in the central channel when the chamber isproperly installed on the heater base. The humidification apparatus canfurther comprise a port cap configured to cover the inlet port forshipping and/or storage, the port cap comprising a leg that extends intothe inlet port. The port cap can be configured to cover the spike forshipping and/or storage. The heater base can further comprise a guardalong a front portion of a rim edge, the guard configured to bedepressed to enable a lower portion of the chamber to slide under therim edge and the guard configured to revert to a non-depressed positiononce the chamber is installed on the heater base.

According to some aspects of the present disclosure, a humidificationapparatus comprises a humidification chamber configured to hold a volumeof liquid and comprising at least one side wall, a top wall connected tothe at least one side wall, a base surface connected to the at least oneside wall, a cavity at least partially defined by the at least one sidewall and the top wall, at least one of the at least one side wall andthe top wall of the humidification chamber having features that define afront of the humidification chamber and a back of the humidificationchamber, an inlet port defining a passage into the cavity of thehumidification chamber, the inlet port having an aperture configured toreceive a first sensor mounted on a heater base, and an outlet portdefining a passage out of the cavity of the humidification chamber andhaving an aperture configured to receive a second sensor mounted on theheater base, wherein an axis extending through the aperture of the inletport is generally parallel to an axis extending through the aperture ofthe outlet port, the axes extending in a front to back direction of thehumidification chamber and the axes extending generally parallel to thebase surface of the humidification chamber.

The humidification apparatus can further comprise a heater baseconfigured to receive the humidification chamber. At least one of the atleast one side wall and the top wall can comprise interlock featuresconfigured to receive corresponding interlock features on the heaterbase to guide insertion of the chamber on the heater base so that thefirst and second sensors are received in the apertures of the inlet andoutlet ports. The interlock features can comprise recesses in the topwall and the interlock features on the heater base comprisecorresponding protrusions, the interlock features of the top wall andthe interlock features on the heater base being engaged through movementalong the axes of the apertures in the inlet port and the outlet port.In some embodiments, the heater base comprises a sensor cartridgecomprising the first and second sensors. The humidification apparatuscan further comprise an inspiratory conduit comprising a chamber endconnector configured to be coupled to the outlet port and at least onesensor and/or heating element, the chamber end connector comprising anelectrical connection configured to couple to a corresponding electricalconnection on the sensor cartridge.

The humidification apparatus can comprise a supply conduit, aninspiratory conduit, and an expiratory conduit, wherein a first end ofthe supply conduit is configured to be coupled to a gases supply, asecond end of the supply conduit comprises a chamber end connectorconfigured to be coupled to the inlet port, a first end of theinspiratory conduit comprises a chamber end connector configured to becoupled to the outlet port, a first end of the expiratory conduit isconfigured to receive gases exhaled by a patient in use, and a secondend of the expiratory conduit is configured to be coupled to the gasessupply. The supply conduit, the inspiratory conduit, and the expiratoryconduit can be coupled to one another to form a one-piece circuit. Thesupply conduit, the inspiratory conduit, and the expiratory conduit canbe coupled with, for example, a mesh wrap, clips, a hook and loopfastener, or a snap fit.

At least part of the chamber end connector of the supply conduit and atleast part of the inlet port can comprise a first indicator. The firstindicator can comprise a first color. At least part of the chamber endconnector of the inspiratory conduit and at least part of the outletport can comprise a second indicator. The second indicator can comprisea second color. The humidification apparatus can further comprise aY-piece, wherein a second end of the inspiratory conduit comprises apatient end connector configured to be coupled to a first branch of theY-piece, the first end of the expiratory conduit comprises a patient endconnector configured to be coupled to a second branch of the Y-piece,and at least part of the Y-piece comprises a third indicator. The thirdindicator can comprise a third color. The supply conduit, theinspiratory conduit, and the expiratory conduit can be held in a loopedconfiguration with a circuit sleeve for shipping and/or storage. Thecircuit sleeve can be positioned on the conduits to hide selectedconnectors to help guide sequential connection of the conduits.

The humidification apparatus can comprise a liquid inlet and a liquidconduit having a first end coupled to the liquid inlet and a second endcoupled to a spike configured to be connected to a liquid source. Thehumidification apparatus can further comprise a winder, and the liquidconduit can extend from the liquid inlet, around the winder, and intothe winder, and the spike can be seated in the winder for shippingand/or storage. The humidification apparatus can comprise a port capconfigured to cover the inlet port and the outlet port for shippingand/or storage. The port cap can comprise legs that extend into theinlet port and the outlet port. The humidification apparatus cancomprise a port cap configured to cover the inlet port for shippingand/or storage, the port cap comprising a leg that extends into theinlet port. The humidification apparatus can comprise a port capconfigured to cover the outlet port for shipping and/or storage, theport cap comprising a leg that extends into the outlet port. The portcap can be configured to cover the spike for shipping and/or storage.

The humidification apparatus can include grips configured to allow anoperator to hold the chamber more easily during installation. The gripscan comprise recesses in the side wall of the chamber. The apertures canbe positioned in the inlet and outlet ports so that the apertures facerearward and the grips are located in a front half of the chamber tohelp orient the chamber for installation on the heater base. The heaterbase can comprise a guard along a front portion of a rim edge, the guardconfigured to be depressed to enable a lower portion of the chamber toslide under the rim edge and the guard configured to revert to anon-depressed position once the chamber is installed on the heater base.

According to some aspects of the present disclosure, a cap for a medicalcircuit can comprise a coupling component and a plug connected to thecoupling component. The plug may comprise a disc and a body. The discmay have a diameter that is larger than the diameter of the body. Thisaids in the at least partial sealing of the circuit. For example, thechannels and the disc provide a tortuous path for dust or contaminantingress into the circuit. The body may comprise at least one segment ofat least one frustoconical taper to facilitate at least partial sealingbetween the cap and an end of a medical circuit. The body may furthercomprise a channel. The channel may be configured to provide apassageway for gases. If a user initiates gases flow in a circuit priorto removing the cap from the circuit, the gases can be released to theatmosphere through the channels. This release of gases reduces thepressure build up within the circuit. The body may comprise acylindrical structure. The body may comprise a first end that is sealedby the disc and a second end that is branched by at least one rib or apair of ribs. The ribs may be perpendicular to each other. The ribs maybe attached to the disc and to an internal wall of the body. The discmay comprise a lip that extends perpendicularly from a perimeter of thedisc. The channel may extend into the lip or into the disc.

The cap can comprise a material that reduces the likelihood of damage tointernal surfaces of the end of the circuit. At least a portion of thebody of the cap can configured to be at least partially received by amedical circuit. The channel can comprise at least one orifice. The atleast one segment of the at least one frustoconical taper can comprise atotal area that is at least 73% of the area of the outer surface of thebody. The disc can comprise an upper surface that is configured toconvey a visual message to a user. The message can be in the form of adrawing, instruction, colour coding, text, or a combination of these.The body can comprise a plurality of channels. The plurality of channelscan comprise a total area that is no greater than 27% of the area of theouter surface of the body. The coupling component can be configured tofacilitate hanging of the cap on a supporting structure. The couplingcomponent can be configured to facilitate hanging the cap, coupled to amedical circuit, on a supporting structure. The coupling component canbe configured to receive a finger. The coupling component can beconfigured to facilitate removal of the cap from the medical circuit.The coupling component can comprise a ring.

For purposes of summarizing the disclosure and the advantages achievedover the prior art, certain objects and advantages are described herein.It is to be understood that not necessarily all such objects oradvantages need to be achieved in accordance with any particularembodiment. Thus, for example, those skilled in the art will recognizethat the disclosure may be embodied or carried out in a manner thatachieves or optimizes one advantage or group of advantages as taught orsuggested herein without necessarily achieving other objects oradvantages as may be taught or suggested herein. All of theseembodiments are intended to be within the scope of the disclosureherein. These and other embodiments will become readily apparent tothose skilled in the art from the following detailed description havingreference to the attached figures, the disclosure not being limited toany particular disclosed embodiment(s).

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentdisclosure will be described with reference to the following drawings,which are illustrative but should not be limiting of the presentdisclosure.

FIG. 1 illustrates a schematic of a humidification system.

FIG. 2A illustrates a humidification chamber installed on a heater base.

FIG. 2B illustrates a humidification chamber.

FIG. 3 illustrates a heater base.

FIGS. 4A-4H illustrate a humidification chamber as packaged.

FIG. 4I illustrates a spike including a sheath.

FIG. 4J illustrates the spike of FIG. 4I without the sheath.

FIGS. 4K-4L illustrate a spike including a sheath.

FIG. 4M illustrates the sheath of FIGS. 4K-4L removed from the spike.

FIG. 5A illustrates a sensor cartridge and a humidification chamber.

FIG. 5B illustrates a sensor cartridge coupled to a heater base.

FIG. 5C illustrates a sensor cartridge connected to a heater base withan electrical cable.

FIG. 6 illustrates a humidification chamber.

FIG. 7A illustrates breathing conduits as packaged.

FIG. 7B illustrates a humidification chamber with features to promoteproper connections.

FIG. 8 illustrates conduits having features corresponding to those shownin FIG. 7B.

FIG. 9A illustrates a one-piece circuit.

FIG. 9B illustrates a releasable connection system for a one-piececircuit.

FIG. 10 illustrates a method for setting up a humidification system.

FIG. 11 illustrates a heater base and a humidification chamber.

FIG. 12 illustrates a chamber installed on a heater base having a sensorcartridge.

FIGS. 13A-13B illustrate the chamber of FIG. 12.

FIGS. 14A-14F illustrate various views of a port cap installed on thechamber of FIGS. 12-13B.

FIGS. 14G-14H illustrate a port cap.

FIGS. 141-14J illustrate the port cap of FIGS. 14G-14H installed on thechamber of FIGS. 12-13B.

FIGS. 14K-14P illustrate a port cap installed on the chamber of FIGS.12-13B.

FIG. 15 illustrates the base having the sensor cartridge of FIG. 12 withthe chamber removed.

FIG. 16 illustrates a side view of an end cap for a Y-piece or conduit.

FIG. 17 illustrates a top perspective view of the end cap of FIG. 19.

FIGS. 18 and 19 illustrate the end cap of FIGS. 16 and 17 coupled to acircuit component and hanging from a medical stand.

FIG. 20A illustrates a perspective view of an alternative end cap.

FIG. 20B illustrates the end cap of FIG. 20A coupled to a Y-piece.

FIG. 21A illustrates a perspective view of an alternative end cap.

FIG. 21B illustrates the end cap of FIG. 21A coupled to the Y-piece.

FIG. 22A illustrates a perspective view of an alternative end cap.

FIG. 22B illustrates the end cap of FIG. 22A coupled to the Y-piece.

FIG. 23A illustrates a perspective view of an alternative end cap.

FIG. 23B illustrates the end cap of FIG. 23A coupled to the Y-piece.

FIGS. 24A-24E illustrate the end caps of FIGS. 16, 20A, 21A, 22A, and23A, respectively, coupled to an alternative Y-piece.

FIG. 25 illustrates a perspective view of a chamber assembly.

FIG. 26 illustrates a front elevation view of a chamber assembly.

FIG. 27 illustrates a front elevation view of a chamber assembly with afeedset attached.

FIG. 28 illustrates a side elevation view of a chamber assembly with theinternal components shown.

FIG. 29 illustrates a front elevation view of a chamber assembly.

FIG. 30 illustrates an enlarged side perspective view of a chamberassembly showing a port cap being removed during insertion.

FIG. 31 illustrates another side elevation view of a chamber assemblywith an alternative port cap.

FIG. 32 illustrates a perspective view of a chamber assembly with afeedset attached.

FIG. 33 illustrates a front elevation view of a chamber assembly.

FIG. 34 illustrates a side elevation view of a chamber assembly.

FIG. 35 illustrates a perspective view of a portion of a port cap.

FIGS. 36 and 37 illustrate perspective views of a portion of a port cap.

FIG. 38 illustrates a schematic of a medical system.

FIGS. 39A-39B illustrate a perspective view of a cap.

FIG. 39C illustrates a top view of a cap.

FIG. 39D illustrates a bottom view of a cap.

FIG. 40 illustrates a perspective view of a cap.

FIG. 41A illustrates a bottom view of a cap.

FIG. 41B illustrates a top view of a cap.

FIG. 42A illustrates a bottom view of a cap.

FIG. 42B illustrates a top view of a cap.

FIGS. 43A-43B illustrate perspective views of caps.

DETAILED DESCRIPTION

Although certain embodiments and examples are described below, those ofskill in the art will appreciate that the disclosure extends beyond thespecifically disclosed embodiments and/or uses and obvious modificationsand equivalents thereof. Thus, it is intended that the scope of thepresent disclosure should not be limited by any particular embodimentsdescribed below.

An example embodiment of a humidification system 100 can include aheater base 102, a humidification chamber 104, and a breathing circuitor breathing circuit assembly, for example, as shown in FIG. 1. In someembodiments, the system 100 further comprises a gases supply 130, forexample, a ventilator or other suitable source of pressurized gasessuitable for breathing or use in medical procedures. The heater base 102can include a heater plate 108 (better shown in FIG. 3). In addition,the heater base 102 can comprise one or more processors 114 and one ormore memories or other suitable storage components. In some embodiments,the heater base 102 also comprises a display that can provideinformation to and/or receive input from an operator.

In some configurations, the display can have a schematic to facilitatethe operator making the desired connections, in some instances in adesired order. For example, the display can have a static image withlights (e.g., LED) under different regions that light in a sequence toencourage the desired connection order. In some configurations, theimage can be formed on membranes that are back-screen printed behind apolyester or polycarbonate film with LEDs attached to or positionedadjacent to the film. In some configurations, the lights may begin thesequence when a switch is operated by insertion of a humidificationchamber into the heater base or the like. Such configurations resolveany need for an operator to turn on the heater base to get the feedbackon proper connection sequence. Other suitable arrangements also can beused.

The humidification chamber 104 generally comprises an inlet 110 and anoutlet 112 and is configured to be installed on the heater plate 108 ofthe heater base 102. The humidification chamber 104 is furtherconfigured to hold a volume of a liquid, such as water. The chamber 104can include an opening or port for the connection of a liquid conduit orfeedset 118. The liquid conduit 118 can extend from the chamber 104, asshown in FIG. 2A. In some configurations, the liquid conduit 118 canconnect to a spike for a water bag. In some configurations, the liquidconduit 118 can be integrally formed with or permanently coupled to thechamber 104. The spike can be coupled to the liquid conduit 118 via anadhesive, sonic welding, an interference fit, or any other suitablemeans. In some embodiments, the spike includes a vent. If the spike isinserted into, for example, a plastic, collapsible bag, the vent isplugged. However, if the spike is inserted into a rigid container, suchas a glass bottle, the vent is open and allows air to enter thecontainer to help reduce or prevent negative pressures in the container.The vent can include a filter that is permeable to gases but impermeableto liquids.

In use, the liquid conduit 118 conveys a liquid, for example, water,from a liquid source, such as a water bag, saline bag, or the like, tothe chamber 104. The heater plate 108 heats the chamber 104 and causesat least some of the chamber 104 contents to evaporate. In someembodiments, the humidification chamber 104 can include features to helpreduce the likelihood of the level of liquid in the chamber 104 fromexceeding a particular level. For example, the chamber 104 can includeone or more floats 150 as shown in FIGS. 2B, 4A, and 4B. The floats riseand fall with the level of liquid in the chamber 104. When the liquidlevel reaches a certain level, the floats 150 obstruct or block the portthat is connected to the liquid conduit 118 to stop or slow furtheringress of liquid into the chamber 104. Other similar features also canbe used. In a preferred embodiment, a plurality of floats 150 are used,each float adapted to stop the further ingress of liquid into thechamber 104. To this end, a second float provides a backup or safetymechanism, thereby further reducing the likelihood of the chamber 104overfilling. FIG. 2B illustrates an example embodiment of such a chamber104 having a primary float 248 a and a secondary float 248 b.

With reference again to FIG. 1, the breathing circuit assembly caninclude a supply conduit 120, an inspiratory conduit 122, and, in someconfigurations, an expiratory conduit 124. A gases supply end of thesupply conduit 120 is configured to connect to an output 132 of thegases supply 130 and a chamber end of the supply conduit 120 isconfigured to connect to the inlet 110 of the chamber 104. A chamber endof the inspiratory conduit 122 is configured to connect to the outlet112 of the chamber 104, and a user end of the inspiratory conduit 122 isconfigured to connect to the user 128 via an interface 126, for example.A user end of the expiratory conduit 124 is configured to connect to theinterface 126, and a gases supply end of the expiratory conduit 124 isconfigured to connect to a return 134 of the gases supply 130. The userends of the inspiratory conduit 112 and expiratory conduit 124 can beconnected to the interface 126 via a Y-piece 127, for example butwithout limitation.

In use, gases flow from the gases supply 130 through the supply conduit120 and into the chamber 104 via the inlet 110. The gases are humidifiedwithin the chamber 104 and exit the chamber 104 through the outlet 112.The user inhales humidified gases supplied through the inspiratoryconduit 122, and exhales into the expiratory conduit 124. Theinspiratory conduit 122 and/or expiratory conduit 124 can each include aheating element, for example, a heating wire, to help maintain the gasesat a desired temperature and to reduce the likelihood of significantcondensation formation in the conduits.

Before use, an operator, such as medical personnel, must correctlyconnect the various components to set up the system 100. Because of thevariety of components and number of connections that must be made,set-up of the system 100 can be a complex process that requires specialtraining to complete properly. The humidification system 100 can includevarious features as described herein to simplify the set-up process andreduce the likelihood of an incorrect set-up. In some embodiments,certain usability features advantageously can help reduce the totalnumber of steps and time required during the set-up process. Somefeatures described herein also can help make set-up more intuitive forthe user, which can reduce the need for specialized in-service training.

To begin set-up, the operator installs the humidification chamber 104 onthe heater base 102 by sliding the chamber 104 onto the heater base 102under a rim edge 106 (shown in FIG. 3) that helps hold the chamber 104in place. The heater plate 108 can be spring loaded in someconfigurations such that the base of the chamber 104 presses downwardupon the heater plate 108 and a protruding portion 105 of the chamber104 can be captured between the heater plate 108 and the rim edge 106.Preferably, a guard 107 along a front portion of the rim edge 106 isdepressed to enable the lower portion of the chamber 104 to access theheater plate 108 and then the guard 107 reverts to a non-depressedposition once the chamber 104 is installed. This advantageously providespositive feedback that the chamber 104 is fully installed on the base102. In some configurations, the forwardmost portions of the rim edge106 (e.g., the portions of the rim edge 106 that define an opening forinsertion of the chamber 104) are configured with a raised or enlargedopening 109 that ramps downward. The opening 109 preferably comprises alower surface that is elevated above an upper surface of thenon-depressed guard 107. In such a manner, the opening 109 provides avisual clue to the operator that the protruding portion 105 can beinserted into the opening 109. Further insertion of the chamber 104 intothe opening 109 causes the guard 107 to be depressed and facilitatesfull insertion of the chamber into the heater base and can help guidethe chamber 104 into place. Thus, these visual details can indicate tothe operator that the chamber 104 slides into place under the rim edge106. This can also help inform the operator that the guard 107 can bedepressed to later remove the chamber 104 from the heater base 102.Preferably, the chamber 104 has details to depress the guard 107 whenthe operator attempts to remove the chamber 104 from the heater base102. Moreover, by providing an uneven upper surface to the rim edge 106,the operator is less likely to believe that the chamber 104 should beplaced atop the rim edge 106, resulting in poor thermal conductivity,because such a placement will lead to an uneven positioning of thechamber 104.

Humidification chambers, such as the chamber 104, often have a generallyrounded shape with generally smooth sides, which can make it difficultfor the operator to hold the chamber 104 during set-up and installation.In setting up the humidifier, the chamber 104 will be grasped and thenslid into position on the heater base 102, as described above.Therefore, as shown in FIG. 4D, the chamber 104 can include grips 168 toadvantageously allow the operator to hold the chamber 104 more easilyduring installation. In some embodiments, for example as illustrated inFIG. 4D, the grips 168 are positioned at particular locations on thechamber 104 to help guide the operator to correctly orient the chamber104 when sliding the chamber 104 onto the base 102. In some embodiments,the grips 168 extend partially or completely around the chamber 104. Thegrips 168 can include one or more of, for example, depressions orcavities on the chamber 104 surface, vertical fins, a textured surface,and/or a handle. In the illustrated configuration, a sidewall of thechamber includes recesses that extend inwardly toward the chamber. Therecesses can include ribs or the like to enhance the ability of a userto grip the chamber by the recesses. The recesses can be positionedalong a forward facing surface. In some configurations, the upwardlyextending ports of the humidifier chamber can include openings that facerearward while the recesses are concave into the humidifier chamber andfacing forward. The forward facing grips help orient the chamber forinstallation. In some configurations, the recesses extend only partiallyup the full height of the chamber. In some configurations, the recessesare opposed to each other such that a gripping force can be applied withfingers and thumb by the user.

With reference to FIG. 4A, the humidification chamber 104 can bepackaged with port caps 160 covering the inlet 110 and the outlet 112.The port caps 160 can seal or generally enclose the chamber 104 duringshipping and storage. In the illustrated embodiment, an intermediatemember extends between and connects the port caps 160, and theintermediate member includes a pull tab or loop 161. The pull tab 161advantageously allows the user to remove the port caps 160 more easilyduring the appropriate stage of set-up. The pull tab 161 is visuallyintuitive such that the user will typically understand that he or she isto pull on the pull tab 161 without requiring additional instructions.The port caps 160 can include legs 162 that extend into the inlet 110and the outlet 112 and that restrain the float 150 in position forshipping. In some configurations, the liquid conduit 118 can be woundaround, and can be contained by, a winder 166 provided on the chamber104. During set-up, after the humidification chamber 104 is installed onthe heater base 102, the port caps 160 can be removed, preferably priorto the liquid conduit 118 being unwound and connected to the liquidsource via a spike 164. Once the spike 164 connects to the liquidsource, liquid will begin filling the chamber 104. However, if theliquid conduit 118 is connected to the liquid source before the portcaps 160 are removed, there is a risk of the chamber 104 overfillingbecause the float 150 is still restrained and cannot function to slow orstop the flow of liquid into the chamber 104.

To reduce the likelihood of overfilling, in some embodiments, thechamber 104 is packaged with the liquid conduit 118 captured between theinlet port 110 and the outlet port 112 of the chamber 104 and the portcaps 160. The liquid conduit 118 can further be somewhat obscured fromthe operator until the port caps 160 have been removed. Preferably,however, the presence of the liquid conduit 118 below the port caps 160can be viewed with the port caps 160 in position, which leads theoperator to remove the port caps 160 to access the liquid conduit 118.Furthermore, removal of the port caps 160 preferably results in theunwinding or unfurling of the liquid conduit 118. This packagingarrangement also reduces or eliminates any need for a winder 166 tocontain the liquid conduit 118 and the set-up steps of removing thewinder 166 from the chamber 104 and unwinding the liquid conduit 118from the winder 166. In some embodiments, the spike 164 and/or liquidconduit 118 are free-floating and not constrained by a winder 166 or theport caps 160. This can help reduce possible operator confusion as towhether the liquid conduit 118 should be unwound during set-up. In somearrangements, the spike 164 freely hangs exposed to further encourageremoval of the port caps 160. In some configurations, the spike 164 ispartially exposed and partially captured by the port caps 160 whichencourage removal of the port caps 160 to access the spike 164.

Additional features can help reduce the likelihood of operatorsmistaking the port caps for operational components of the systemintended to remain in place during use. For example, an alternative portcap 170 can include a single flat surface spanning the top of both portsand simple side faces encircling the ports and, optionally, the liquidconduit 118 as shown in FIGS. 4B and 4C. This design can give the portcap 170 the appearance of a lid to be removed from the chamber 104before use. The port cap 170 can also include a lip detail around someor all of a perimeter of the flat top surface that the operator can gripfor removal. The flat top surface provides a surface for an optionalinstruction label or a label having an image of, e.g., a trash can toindicate to the operator that the port cap 170 is supposed to be removedand discarded. In some configurations, the port caps can be formed of amaterial or have a coloration that will confirm an instinct to disposeof the port caps.

With reference to FIG. 4D, another example embodiment of a port cap 170that can be used with a winder 166 includes a cap body 172 and a floatretainer 174 having a tab or pull loop 176 and legs 162 that extend intothe inlet 110 and the outlet 112 to restrain the float 150. The cap body172 can be formed to be at least partially translucent or substantiallytransparent to reveal the conduit contained within the cap body 172. Thecap body 172 can include an arrow and/or other visual or otherindicators to direct the operator on the correct direction for insertionof the chamber 104 on the heater base 102. In some embodiments, the capbody 172 can include a label that includes instructions for set-up ofthe chamber to increase the likelihood of a correct or desired sequenceof set-up steps being followed by people performing set-up operations.In some embodiments, the float retainer 174 is separate from the capbody 172 and can be removed from the chamber 104 before the cap body 172as shown in FIG. 4E. Removal of the cap body 172 exposes the winder 166,as shown in FIG. 4F. Alternatively, the float retainer 174 can beintegrally molded with or coupled to the cap body 172 so that bothcomponents are removed simultaneously, for example, by pulling on thepull loop 176. The pull loop 176 can advantageously allow the port cap170 to be removed more easily. Both embodiments advantageously ensurethat the float retainer 174 is removed when the winder 166 is exposed sothat the float 150 is unrestrained before the liquid conduit 118 isconnected to the liquid source. In some embodiments, the winder 166 iscoupled to the chamber 104 with clips or other features that connect to,clip to or otherwise engage the chamber ports. As shown in FIG. 4F, theliquid conduit 118 can extend from a liquid inlet 117 in the chamber104, around the winder 166, and into the winder 166 through a vent 167to couple to the spike 164, which can be seated within the winder 166 asshown in the illustrated embodiment. In the illustrated embodiment, thecap body 172 is sized and shaped to also cover the liquid conduit 118when in place for shipping and/or storage. In some configurations, thewinder 166 includes features to secure the spike in a horizontalposition (e.g., a shipping position) and in a non-horizontal or verticalposition (e.g., a testing position). For example, the winder 166 canhave a generally oval shape and can include a longitudinal receptacle186 within the winder 166 configured to receive and/or to secure thespike in a horizontal shipping position. The winder 166 can also includea generally circular receptacle 188 configured to receive a grip portion190 of the spike 164 (shown in FIG. 4J) so that the spike 164 can beplaced in a generally vertical position for testing. The liquid conduit118 can be secured in the liquid inlet 117 with an adhesive such as glueor any other suitable technique. A tubing holder 119 can help secure theliquid conduit 118 to a portion of the winder 166 or to the top of thechamber 104 and help route the liquid conduit 118 from the liquid inlet117 to the winder 166. In some embodiments, the operator can remove thespike 164 from the winder 166 and unwind the liquid conduit 118 from thewinder 166 to connect the spike 164 to the liquid source. In someembodiments, the operator can remove the winder 166 from the chamber 104and discard the winder 166 after unwinding the liquid conduit 118.

Additional embodiments of liquid conduit 118 packaging are shown inFIGS. 4G and 4H. In both illustrated embodiments, the liquid conduit 118is wound into a looped configuration, for example, by winding the liquidconduit 118 around a jig. In some embodiments, a label 218 is attachedto the liquid conduit before winding and used to secure the liquidconduit 118 in the looped configuration. In the embodiment of FIG. 4G,the looped liquid conduit 118 is placed within a foldable card 178coupled to the top of the chamber 104. The card 178 can be made ofcardboard, plastic, a flexible material, or any other suitable material,and a bottom portion 178 a can be secured to the chamber 104 with anadhesive and/or by cutouts 280 configured to be placed around thechamber inlet and outlet ports. A top portion 178 b of the card 178 canbe folded over the bottom portion and secured with cutouts configured tobe placed around the chamber inlet and outlet ports and/or with portcaps 160. In some embodiments, the spike 164 is secured to a base of thecard 178 between the top and bottom portions via a slot or clip. Thebottom portion 178 a of the card can include a slit 282 to accommodatethe liquid conduit 118 extending between the card 178 and the liquidinlet 117. In some configurations, the looped conduit can be placedwidth-wise on the card. In the embodiment shown in FIG. 411, the loopedliquid conduit 118 is placed in a molded cavity 111 on the top of thechamber 104 and protected by a tube enclosure 179, which can includeport caps 160. A bottom surface of the tube enclosure 179 can include afeature to secure the spike 164. In some embodiments, a label withbranding, instructions, and/or other information can be attached to thetube enclosure 179, the card 178 (e.g., the top portion 178 b or thecard 178). In other words, in some configurations, one or more of thecard (e.g., the top portion 178 b of the card 178) and the tubeenclosure 179 can incorporate one or more surfaces that can be used forinstructions (e.g., unpacking instructions, set-up instructions or thelike), labels or warnings. In some configurations, the card 178 caninclude sequential instructions that increases the likelihood of acorrect or desired sequence of set-up steps being followed by peopleperforming set-up operations. For example, the card 178 can be providedwith sequential or staggered steps to follow. In some configurations,the card 178 or another component can explain only steps that involveexposed or accessible components.

As shown in FIGS. 4F and 4I, the spike 164 can be packaged with a spikecap or sheath 165 that the operator removes before use, as shown in FIG.4J. The sheath 165 can include a tab or a similar feature for easierremoval of the spike 164 from the winder 166 and/or of the sheath 165from the spike 164. In the illustrated embodiment, the sheath 165includes a loop or ring 265. If desired, the user can use the ring 265to hang the sheathed spike 164 on, for example, a medical stand, untilthe user is ready to use the spike 164. FIGS. 4K-4L illustrate anotherexample embodiment of a spike 164 packaged with a sheath 165 including aring 265. FIG. 4M shows the sheath 165 alone. As shown in FIGS. 4L and4M, the ring 265 can be lifted to an approximately 90° angle relative tothe sheath 165 to allow the user to more easily grasp the ring 265and/or more easily hang the ring 265 on a medical stand. In someconfigurations, the cap is not connected to any other member such thatthe operator knows to remove the cap. Labels also can be used toinstruct the operator on how to set up the liquid conduit 118 and liquidsource. Typically, humidification systems 100 utilize water to humidifygases passing through the humidification chamber 104. To indicate to theoperator that the spike should be connected to a water bag rather toanother type of liquid, such as saline, the liquid conduit 118 and/orthe chamber 104 can include labels, reading “H₂O.” Preferably, any suchvisual indicator, including the label, is positioned closer to the spikethan to the body of the chamber when the conduit is stretched outward.The label on the liquid conduit 118 can also help draw the operator'sattention to the water spike 164, which may not be obvious to theoperator when concealed by the spike cap. The chamber 104 can alsoinclude labels to indicate the appropriate water level.

In some configurations, a spike can be secured to tubing using anysuitable technique. For example, the spike can be secured to tubingusing adhesives, sonic welding, interference fit, or the like. A labelthen can be attached to the tubing. In some configurations, the labelcan be loosely looped over the tubing and can include a sticky end(e.g., exposed adhesive). In some configurations, the label can bepositioned closer to the spike than to another end of the tubing. Thetubing can be wound around a jig or the like and secured in a loopedconfiguration using the label (e.g., using the sticky end to tack theend of the label to another portion of the label). When winding thetubing, the ends preferably are provided with enough slack to connectthe tubing and spike to the chamber. The end without the spike can besecured to the chamber using any suitable technique. In someconfigurations, the end without the spike can be inserted into a waterinlet hole of the water chamber and fixed with glue or the like. Theends of the loop of tubing can be placed over or between the inlet andoutlet ports of the chamber. The spike can be secured into a receptacle.In some configurations, the receptacle can be formed in, or secured to,a portion of the chamber. In some configurations, the spike is securedto the chamber with the point extending away from the chamber fortesting. Testing can be conducted on the assembled chamber. Aftertesting, the spike can be removed from the chamber and the spike andtubing can be secured in any suitable manner for shipping, includingthose set forth above.

The humidification system 100 can include reusable temperature and/orflow probes at or near the humidification chamber 104. For example, aflow sensor can be positioned in the chamber inlet 110 to sense the flowrate of the gases entering the chamber 104 from the gases supply 130. Atemperature sensor can be positioned in the chamber inlet 110 to sensethe temperature of the gases entering the chamber 104 from the gasessupply 130. A temperature sensor can be positioned in the chamber outlet112 to sense the temperature of the humidified gases leaving the chamber104. A flow sensor can also or alternatively be positioned in thechamber outlet 112 to sense the flow rate of gases leaving the chamber104 to be delivered to the user.

Reusable temperature and/or flow sensor probes 206 can be integratedinto a sensor cartridge module 200, as shown in FIG. 5B. FIG. 5C showsthe sensor cartridge module 200 connected to the heater base with anelectrical cable. The sensor cartridge module 200 in FIG. 5B, however,is mechanically and electrically connected to the heater base 102 via aspine 210 and can therefore provide for the transfer of power to thesensors while also providing a mounting location for the sensors, forexample but without limitation. In some configurations, the spine 210and the port cap can have an interfacing configuration such thatmovement of the chamber with the port cap in position toward the spineduring mounting of the chamber to the heater base will cause the spineto lift the port cap from the chamber. Such a configuration increasesthe likelihood of the operator removing the port cap from the chamber.Other suitable configurations also can be used.

The sensor cartridge module 200 also allows for the transfer of databetween the sensors and the processor 114 in the heater base 102. Thechamber inlet 110 and outlet 112 can have apertures 140, 142therethrough, for example as shown in FIG. 6. Probe membranes orgrommets 144 sized and shaped to receive the temperature and/or flowprobes 206 can be positioned within and pneumatically seal the apertures140, 142. In the configuration of FIG. 5B, the operator is encouraged toposition the chamber base below the rim edge 106 because otherwise theprobes attached to the spine will not properly align with the respectiveapertures.

Correct insertion of the chamber 104 into the heater base 102 canautomatically position the sensor probes 206 within the apertures 140,142 of the chamber inlet 110 and outlet 112. This can advantageouslyallow for an easier set-up compared to separate reusable sensors, whichmust be manually inserted and electrically connected to the heater base102, and reduce the possibility of improper electrical connection,improper pneumatic sealing and/or assembly. The probe membranes 144protect the probes from direct contact with the gases passing into andout of the chamber 104. The probes therefore can be reused withoutrequiring cleaning and storage of the probes 206 and disconnection andreconnection of wires between uses.

To help guide the operator through installation of the chamber 104 onthe heater base 102 and proper connection with the sensor cartridgemodule 200, the chamber 104 and sensor cartridge module 200 can includelead-in features, such as corresponding male and female connections. Forexample, one or more of the base 102 and the cartridge module 200 caninclude structures that mate with structures 201 on the chamber 104. Inthe configuration of the chamber 104 shown in FIG. 4F, the structures201 are recessed portions. Thus, the chamber 104 can have a shortervertical height on the portion closest to the heater base 102 whenmounted while the chamber 104 has a taller vertical height on theportion that is positioned away from the cartridge module 200. Such aconfiguration reduces the likelihood of the chamber being inserted intothe base 102 backwards, which can result in damage to the sensors. Thecooperating formations greatly increase the likelihood that coupling ofthe chamber 104 to the base 102 is only achieved in a correct rotationalorientation of the chamber 104. Moreover, the cooperating structures canprovide visual cues to the proper rotational orientation of the chamber104. The cooperating structures can be a male on the base and a femaleon the chamber, a female on the base and a male on the chamber, or anycombination of male and female portions on the base and the chamber.

By way of another example, the sensor cartridge module 200 can include acentral male projection 202 configured to slide into a female recess 204in the chamber 104. Alternatively, the chamber 104 can include a maleprojection configured to slide into a center of the sensor cartridgemodule 200. Preferably, the female recess 204 is configured in such amanner that only one orientation of the chamber relative to the maleprojection 202 is possible. Any other configuration or snap togetherassembly can be used. In some configurations, the chamber 104 caninclude a chamfered or angled edge or protrusion 205 on the lateralsides, for example, but without limitation. These protrusions 205 cancooperate with a structure of the base 102 or on the cartridge module200. The cooperation preferably helps to pull or encourage the chamber104 into a fully seated position relative to the base 102. Thus, theprotrusions 205 and the cooperating structures provide another exampleof structures that can orient and properly position the sensor probes206 relative to the chamber. These means for orienting the chamberrelative to the heater base also advantageously aid proper positioningof the sensor probes 206 within the chamber ports. Advantageously, whenthe chamber 104 docks on the sensor cartridge module 200, the sensorprobes can be automatically inserted into the chamber ports to theappropriate distance or depth. In other words, the risk of the probes206 not fully inserting to the ports of the chamber 104 can be reducedor eliminated. Preferably, the connection between the sensor cartridgemodule 200 and the chamber 104 is generally horizontally (e.g., parallelwith an upper surface of the heater plate).

In some configurations, the chamber can have recess that accommodates aprotrusion from the spine or other portion of the heater base. Such aconfiguration can help guide the chamber into position on the heaterbase in a desired rotational orientation. In some configurations, ratherthan being translated into position, the chamber can be rotated intoposition on the heater base. For example, slots can be provided withposts that can slide vertically downward into the slots such thatrotation of the chamber will position the posts under the rim edge 106.In some configurations, if the sensor cartridge module 200 is mounted tothe chamber before the chamber is mounted to the heater base, rotationof the chamber can establish an electrical connection between componentsmounted to the chamber (e.g., sensors) and the heater base. Rotation ofthe chamber also defines a horizontal connection direction. Otherconfigurations also are possible.

Some humidification systems 100 also include temperature and/or flowrate sensors at various locations in the breathing circuit to monitorconditions of the gases as they travel through the system 100 to andfrom the user 128. Some such systems include reusable temperaturesensors at or near the user end of the inspiratory conduit 122 to ensurethe gases reaching the user 128 are at an appropriate temperature.Because the various conduits of the circuit are typically disposable,reusable temperature sensors must be separately coupled to theinspiratory conduit 122 during set-up and must further be connected tothe heater base 102 for power and data transfer. The user may forget toconnect the sensor and/or sensor cable entirely, or may inadvertentlyfail to fully insert the sensor into the inspiratory conduit 122, whichcan skew the sensor data. According to some embodiments of the presentdisclosure, a single-use user end temperature sensor and associatedsensor cable can be integrated with the inspiratory conduit 122. Thiscan advantageously eliminate the steps of connecting a separate sensorand sensor wires during set-up, as well as the steps and time requiredto clean and store reusable sensors.

In some embodiments, the sensor cartridge module 200 can allow for powerand data transfer between the heater base 102 and the inspiratoryconduit 122 user end temperature sensor and an inspiratory conduit 122heater wire. The inspiratory conduit 122 chamber end connector caninclude an electrical connection for coupling to a correspondingconnection on the sensor cartridge module 200. This provides a simpleralternative to using a reusable sensor cable to provide an electricalconnection between the user end temperature sensor and the heater base102 and a reusable heater wire adapter cable to provide an electricalconnection between the inspiratory conduit 122 heater wire and heaterbase 102. The user end temperature sensor and heater wire can be coupledto the electrical connection of the inspiratory conduit 122 chamber endconnector via wires that are integrated in or run alongside the exteriorof the inspiratory conduit 122.

If the expiratory conduit 124 includes a heating element, e.g., a heaterwire, the heating element is typically powered via an electrical cableconnecting the heating element to the heater base 102. To help simplifyset-up, both ends of the heating element electrical cable can have plugsof the same design. Corresponding sockets can be located on the heaterbase 102 and the expiratory conduit 124 gases supply end connector.Either end of the heating element electrical cable can be coupled toeither the expiratory conduit 124 gases supply end connector socket orthe socket of the heater base 102. The operator therefore does not needto spend excess time determining the correct orientation for the heatingelement electrical cable.

As explained herein, the breathing circuit can include multiple conduitsrequiring multiple connections to the chamber 104, the interface 126,and/or the gases supply 130. The length of the conduits can make themdifficult to handle and control during set-up, increasing the risk ofthe conduits being accidentally dropped on the ground and possiblycontaminated. To improve handling and control during removal frompackaging and set-up, the circuits can be packaged and held together ina looped configuration with a circuit sleeve 260 as shown in FIG. 7A. Insome embodiments, the sleeved conduits can be packaged in a protectiveplastic bag or the like. In some embodiments, the circuit sleeve 260 ismade of cardboard or a thin plastic sheet, although other materials arealso possible. The circuit sleeve 260 can be looped or wrapped aroundthe conduits and closed or held together with, for example, staples,tape, and/or an adhesive, e.g., glue. In some embodiments, ends of thesleeve 260 have interlocking features to close the sleeve 260 around theconduits, for example, interlocking slits or a tab and correspondingslot. The conduits can also be held in a looped configuration by tape,rubber bands, straps, or the like.

The looped configuration can advantageously allow the operator to hangthe conduits on, for example, the forearm, the heater base, or anotherobject to free up the operator's hands for other set-up tasks. In someembodiments, the circuit sleeve 260 includes a hole 262 that can be usedto hang the looped conduits on a hook, for example, a hook used to hangthe water bag or an I.V. bag, as an alternative to placing the conduitson other hospital surfaces that can increase the risk of contamination.The circuit sleeve 260 can be positioned on the conduits to concealselected conduit connectors and help direct the operator's attention tovisible conduit connectors, which can be the connectors that should beconnected first during the set-up process. If the operator makes theappropriate connections with the visible conduit connectors beforeremoving the circuit sleeve 260 to expose the remaining connectors, theoperator will have a reduced number of possible connections, therebymaking it easier and more likely to correctly complete the set-up. Insome embodiments, the circuit sleeve 260 can include set-upinstructions, in writing and/or pictures, to help direct a preferredset-up sequence to achieve the correct set-up. The circuit sleeve 260can also be positioned on the conduits to cover and/or isolate any sharpedges or corners (e.g., portions of the connectors) to help reduce thepossibility of damage to, for example, other circuit components, thechamber, and/or the packaging material during shipping or the like.

To help reduce the likelihood of incorrect connections during set-up,the conduit connectors, chamber inlet 110 and outlet 112, gases supplyoutput 132 and input 130, interfaces 126, and/or Y-piece 127 can havevarying diameters to help prevent incorrect connections from being made.In some embodiments, some or all of the connections can include details,such as rib details, that allow the appropriate components to beconnected, but inhibit improper connections. For example, the chamberoutlet 112 or inspiratory conduit port can include a rib detail 250circumferentially surrounding the port 112 as shown in FIG. 7B. Theinspiratory conduit chamber connector can include a corresponding ribdetail 254 configured to engage the chamber outlet port rib detail 250as shown in FIG. 8. The chamber inlet or supply conduit port cansimilarly include a circumferential rib detail 252 to engage acorresponding rib detail 256 on the supply conduit chamber connector.Other components, such as an inspiratory tube user end connector,expiratory tube user end connector, expiratory tube gases supply endconnector, and/or supply conduit gases supply end connector can includeoutwardly extending rib details. In some configurations, differentdiameters can be used to make it difficult if not impossible tophysically connect the wrong conduit to the wrong port. In addition, asdescribed above, it is possible to form each end of each hose to have aunique configuration to help reinforce the desired connections. Otherconfigurations are also possible.

In some embodiments, various components can be color coded to help guidethe operator through the set-up process and help reduce the likelihoodof incorrect connections. For example, the supply conduit 120 chamberend connector and chamber 104 inlet 110 port can be similarly colored toa first color, for example, green, to indicate to the operator thatthose two components are intended to be connected. Similarly, theinspiratory conduit chamber end connector and chamber outlet port can becolor-coordinated to a second color, for example, blue. For a dual-limbcircuit, the interface 126 and/or Y-piece 127 can be color-coordinatedto a third color, for example, grey. For a single-limb circuit, theinterface and the inspiratory conduit patient-end connector can becolor-coordinated to a fourth color, for example, blue. The sensorcartridge module 200 temperature and flow probes 206 can becolor-coordinated with probe membranes 144, for example turquoise. Anadapter cable and plugs for the expiratory conduit heating element canbe color-coordinated with sockets on the expiratory conduit gases supplyend connector and the heater base 102, for example, yellow. Thecomponents intended to be discarded during set-up, for example, the portcaps 160, 170, winder 166, a Y-piece cap, and/or a cap for the waterspike 164 can be colored similarly, for example, semi-transparent yellowor orange. Preferably, the cap for the water spike 164 is transparent,translucent or otherwise configured with slots, gaps, holes or the liketo indicate to the operator that the spike is positioned within the cap.The supply conduit gases supply end connector and expiratory conduitgases supply end connector can be color-coded, for example, pink. Insome embodiments, the conduits themselves can be differentiated throughcolor. For example, the supply conduit 120 can be green, the inspiratoryconduit 122 can be blue, and the expiratory conduit 124 can be white. Insome embodiments, colors may be selected so that operators with reducedcolor recognition (such as red-green color blindness) are still able todifferentiate the different components. In some arrangements, where anorder is preferred, the color coding to be that over color mixing (e.g.,red for first connections, orange for second connections, yellow forthird connections, green for fourth connections and blue for fifthconnections, for example but without limitation). Thus, patterns can beused to encourage proper progression as well as proper connections. Insuch configurations, LED, lights or color filters over lights can beused to show the color of the connections on the electric display or thecolors can simply be shown on a display screen. Of course, otherconfigurations and color palettes are also possible. In someembodiments, user instructions and/or errors can refer to the differentcomponents by their color.

In addition to or instead of color-coordinating the various components,the components can include corresponding symbols and/or text to indicateparts intended to be connected together. In some configurations, thefirst connections can be labeled “1” or “A” with the second connectionsbeing labeled “2” or “B,” by way of example. In some embodiments, one ormore of the conduits can include labeling indicating the properdirection of gas flow through the conduit in use. For example, thesupply conduit 120 can include one or more arrows and, optionally, textsimilar to “TO HUMIDIFIER,” pointing from the gases supply 130 end tothe chamber 104 end. Similarly, the inspiratory conduit 122 can includearrows and optional text (e.g., “TO PATIENT”) pointing from the chamberend to the user end, and the expiratory conduit 124 can include arrowsand optional text (e.g., “FROM PATIENT”) pointing from the user end tothe gases supply end. Any suitable combinations or selection of shapes,colors, sizing, and/or symbols can be used to help a user make thedesired connections and/or make the desired connections in the desiredorder. Further, in some embodiments, connectors of different componentsmay be configured not to be able to connect to one another. For examplebut without limitation, the inspiratory conduit can have a connectorthat connects to only the outlet of the humidifier. In such embodiments,the connectors would reduce the likelihood of improperly connecting thecomponent because the components would be very difficult, if notimpossible, to connect incorrectly.

To further simplify set-up of the breathing circuit, in someembodiments, the supply 120 conduit, the inspiratory 122 conduit, and,optionally, the expiratory 124 conduit can be coupled into a one-piececircuit, for example as shown in FIG. 9A. In some embodiments, the userends of the inspiratory 122 conduit and the expiratory 124 conduit canbe coupled to a Y-piece 127 configured to be coupled to the interface126 in use. The Y-piece 127 can be packaged with a disposable cap 180covering the user end to help inhibit contamination of the conduits andconnections during set-up. The electrical connectors and cables fortemperature and flow sensors and heating elements can also be integratedinto the one-piece circuit. In some embodiments, the chamber 104 can beprovided pre-coupled with the one-piece circuit as well.

The conduits can be joined together or coupled via, for example, amesh-type wrap or sheath surrounding at least some portion of theconduits. In some configurations, multiple portions of the conduits tobe joined to form a multiple lumen structure can be joined with separateconnecting means, including but not limited to mesh-type wrap, sheaths,belts, connectors, clips or the like. In some embodiments, the supplyconduit 120 and the inspiratory conduit 122 can be removably coupled tothe expiratory conduit 124 with individual clips. This canadvantageously allow for the expiratory conduit 124 to be unclipped fromthe supply 120 conduit and the inspiratory 122 conduit and removed fromthe circuit when not needed.

In some embodiments, two or more of the conduits are structured toreleasably connect together. In some embodiments, all of the conduitsare structured to releasably connect together. A first conduit (e.g.,the inspiratory conduit) can comprise a first portion of one of a hookmaterial or a loop material and a second conduit (e.g., the expiratoryconduit) can comprise a second portion of the other of a hook materialor a loop material. The first and second portions can be configured toreleasably connect together in a hook-and-loop arrangement. Otherreleasable connection systems can additionally or alternatively be used,such as a series of magnets whereby the two portions include magnets ofopposite polarity, for example but without limitation. In anotherconfiguration, the outer wall of the inspiratory conduit and the outerwall of the expiratory conduit can be corrugated such that the peaks andtroughs of the corrugation are mushroom-shaped. In such a configuration,the peaks of one conduit are configured to releasably snap-fit into thetroughs of the other conduit such as shown in FIG. 9B, for example butwithout limitation. In such a configuration, the conduits may bedirectly connected to one another. The size and shape of the peaks andtroughs can be the same on both conduits or can be complementary toreduce or eliminate the likelihood of, for example but withoutlimitation, two expiratory conduits connecting together.

The one-piece circuit advantageously reduces the number of connectionsrequired during set-up and reduces the possibility of incorrectassembly. Additionally, during set-up of traditional systems, thevarious components may be placed on a table or bed to allow for sortingand identification. Components can be misplaced or fall to the floor,thereby risking damage and/or contamination. The one-piece circuitadvantageously helps reduce these problems. The one-piece circuit withintegrated electrical connectors and cables also allows for the variouselectrical connections to be made during set-up with the components tobe connected being positioned in close proximity to each other. In someembodiments, a heating element connector plug 182 of the expiratoryconduit 124 can be located along the length of the expiratory conduit124 rather than at the gases supply 130 connector. The plug 182 can bepositioned and configured to be connected to a socket on the sensorcartridge module 200 or elsewhere on the heater base 102, for example,on the front of the heater base 102 to improve visibility of and accessto the socket. In such embodiments, the plug 182 may be automaticallyconnected to the sensor cartridge module 200 when the expiratory conduit124 and/or the chamber 104 is connected to the heater base 102.

Various features can help improve the ergonomics of the humidificationsystem 100. For example, the socket on the expiratory conduit gasessupply end connector can be oriented at, for example, about a 45° anglefrom a plane defined by the end of the conduit. The angle can enhancethe visibility of the socket when the expiratory conduit 124 isconnected to the either horizontally or vertically oriented return 134of the gases supply 130. The angle can also help reduce the likelihoodthat the socket will be obstructed by other components or equipmentmaking set-up more difficult. The heater base 102 socket can be locatedon a front face of the heater base 102 to enhance visibility and ease ofaccess as compared to placement of the socket on, for example, a side ofthe heater base 102 or elsewhere.

In some embodiments, the expiratory conduit 124 gases supply 130 endconnector and/or the supply conduit 120 gases supply 130 end connectorcan have an elbow shape. For example, the connectors can have an angleof about 120°. The elbow shape can advantageously allow the operator toposition the direction of the expiratory conduit 124 and/or supplyconduit 120 to and from the gases supply 130 so that the conduits do notobstruct other system components, such as the heater base 102 display.Any or all of the connectors, such as one or more of the expiratoryconduit 124 and the supply conduit 120 gases supply end connectors andthe inspiratory conduit 122 and the expiratory conduit 124 user endconnectors can include grip details to help the operator more easilygrip the connectors and perform a twisting motion for inserting andremoving medical taper connectors. The grip details can be especiallybeneficial for operators wearing surgical gloves.

In some embodiments, the heater base display 103 can be located on anupper surface of the spine 210, for example as shown in FIG. 11, foreasier viewing. In the illustrated embodiment, the upper surface of thespine 210 and therefore the display 103 are oriented at an angle. Theangled orientation can advantageously allow for an improved or easierview of the display 103 for the operator, particularly, for example, ifthe heater base 102 is positioned below the operator's horizontal lineof sight. In some embodiments, the upper surface and/or display 103 canbe oriented at an angle of about 22° from vertical, although otherangles are also possible. In some embodiments, one or both of the supplyconduit and inspiratory conduit chamber end connectors can have anangled or elbow shape. For example, in the embodiment of FIG. 11, thesupply conduit chamber end connector 257 has an elbow shape so that itcan be angled away from the heater base 102. The angled or elbowconfiguration can advantageously inhibit or prevent the connector and/orconduit from substantially obscuring the display 103, which serves toimprove display visibility. In some embodiments, one or both of thesupply and inspiratory conduit chamber end connectors can have an angleof about 112° so that the connector extends from the chamber port at anangle of about 22° above horizontal when coupled to the port, althoughother angles are also possible. In some embodiments, the spine 210,display 103, and/or one or both chamber end connectors can be configuredso that the connector(s) is below the display 103 and/or a bottom edgeof the upper surface of the spine 210, e.g., the connector(s) extendsbelow a line extending from the bottom edge of the display 103perpendicular to the plane of the display and/or below a line extendingfrom the bottom edge of the upper surface of the spine 210 perpendicularto the plane of the upper surface.

Additional features can assist the operator with the overall set-upprocess. For example, packaging for the consumable components of thesystem 100 can include a schematic diagram illustrating the set-upprocedure and/or step-by-step instructions. FIG. 10 illustrates asequential method for setting up a humidification system 100. The methodcan include some or all of: installing the chamber 104 on the heaterbase 102, removing the port cap(s) 160, 170, removing the spike 164 fromthe winder 166, unwinding the liquid conduit 118 and removing the winder166 from the chamber 104, coupling the spike 164 to a liquid source,coupling the supply conduit 120 to the chamber inlet 110, coupling thesupply conduit 120 to the gases supply 130, coupling the inspiratoryconduit 122 to the chamber outlet 112, and coupling the inspiratoryconduit 122 to the Y-piece 127 or interface 126. The method can furtherinclude coupling the expiratory conduit 124 to the interface 126 or theY-piece 127 and the gases supply 130.

Another example embodiment of a humidification chamber 304 installed ona heater base 302 having a sensor cartridge module 400 is shown in FIG.12. The heater base 302, sensor cartridge module 400, and/or chamber 304can include any of the features shown and described herein with respectto other embodiments.

Like the heater base display 103 of FIG. 11, the heater base display 303of the heater base 302 shown in FIG. 12 can be located on an uppersurface of the spine 301 for easier viewing. The upper surface of thespine 301 and therefore the display 303 can also be oriented at an angleas shown to allow for an improved or easier view of the display 303. Insome embodiments, the upper surface and/or display 303 can be orientedat an angle of about 22° from vertical, although other angles are alsopossible. In some embodiments, the display 303 or one or more portionsof the display can be touchscreen. The display 303 can includetouchscreen portions in combination with physical buttons, knobs, and/orthe like. Touchscreen portions can advantageously provide greater userinteraction possibilities than physical buttons and knobs alone. In someembodiments, the display 303 can include any of the features describedin U.S. Provisional Application No. 61/893,758, filed Oct. 21, 2013, theentirety of which is hereby incorporated by reference herein.

Similar to humidification chamber 104, humidification chamber 304includes a protruding portion 305, an inlet 310, an outlet 312, and aliquid inlet 317, as shown in FIGS. 13A-13B. As shown, the liquid inlet317 can be positioned near a front of the chamber 304. The liquidconduit 118 can extend from the liquid inlet 317 and can be secured inthe liquid inlet 317 with an adhesive such as glue or any other suitabletechnique. This placement places the liquid conduit 118 farther from theheater base display 303, which can advantageously reduce possibleobstruction of or interference with the display 303 by the liquidconduit 118. This can be particularly advantageous if the display 303 isa touch screen display such that contact by the liquid conduit 118 couldbe interpreted as a display input. Placement near the front of thechamber 304 can also help prevent or inhibit the liquid conduit 118 frombeing caught between the heater base 302 and chamber 304 when thechamber 304 is installed on the heater base 302. In the illustratedembodiment, the inlet 310 extends upward from the chamber 304, and theoutlet 312 has an elbow shape such that the outlet 312 extends upwardthen bends to extend toward the front of the chamber 304. In otherwords, the outlet 312 extends away from the heater base 302 when thechamber 304 is installed on the heater base 302. In the illustratedembodiment, the outlet 312 bends to an angle of about 90°.

In some embodiments, the chamber 104 can be packaged with a single portcap 360, 360 a, 360 b having a single float-retaining leg, for exampleas shown in FIGS. 14A-14P. In the illustrated embodiments, the port cap360 is configured to cover the inlet 110, and the float-retaining legextends into the inlet 310 to restrain the float(s). As shown, the portcap 360 can also cover the spike 164. Covering the spike 164 with theport cap 360 can advantageously encourage the user to remove the portcap 360 before use, thereby freeing the float(s). Positioning the spike164 under the port cap 360 also prevents or inhibits the user from beingable to connect the spike 164 to a water bag before the float-retainingleg has been removed from the inlet 310 to free the float(s) so that thefloat(s) can function to, for example, prevent or inhibit overfill.

Use of a single port cap 360 can advantageously allow for the outlet 312to have an elbow configuration as compared to capping both the inlet 310and outlet 312 ports. In some embodiments, the chamber 304 is shippedand stored in a hygienic consumable package. Therefore, leaving theoutlet 312 uncovered does not significantly increase the risk ofcontamination of the chamber 304 during shipping or storage. A singleport cap 360 can also allow for the inspiratory conduit 122 to bepreassembled with the chamber 304 if desired. In some embodiments, theinspiratory conduit 122 includes a connector configured to couple theconduit 122 to the outlet 312. For example, the connector and/or outlet312 can include various features as described in U.S. ProvisionalApplication No. 61/919,485, filed Dec. 20, 2013. The connector can beconfigured to clip onto the chamber 304, which can advantageously allowfor the inspiratory conduit 122 and chamber 304 to be preassembled inthe packaging for shipping and storage. This can advantageously reducethe number of connections the user is required to make.

In the embodiment of FIGS. 14A-14F, the port cap 360 a includes a firstportion 362 a configured to cover the inlet 310 and a second portion 364a that extends forward from the first portion 362 a and is configured tocover the spike 164 in a shipping position, as shown in FIGS. 14B, 14D,14F. In some configurations, the spike 164 can be in a horizontalshipping position. A top surface of the first portion 362 a can bedownwardly offset from a top surface of the second portion 364 a so thatthe top of the first portion 362 a is at least substantially flush withthe top of the inlet port 310. In the embodiment of FIGS. 14K-14P, theport cap 360 b includes a first portion 362 b configured to cover theinlet 310, a second portion 364 b configured to cover the spike 164 in avertical shipping position adjacent the front of the chamber 304 asshown in FIGS. 14L, 14N, and 14P, and a ramped intermediate portion 363extending between and connecting the first portion 362 b and the secondportion 364 b.

The second portion 364 a, 364 b of the port cap 360 a, 360 b can includefeatures configured to retain the spike 164 when the port cap 360 a, 360b is removed from the chamber 304, for example as shown in FIGS.14G-14H. In some embodiments, the port cap 360 a, 360 b includes a hook,loop, hole or the like that a user can use to more easily remove theport cap 360 a, 360 b and/or to hang the port cap 360 a, 360 bcontaining the spike 164 on a medical stand until the user is ready toconnect the spike 164 to a water bag. For example, FIGS. 14G-14Jillustrate a port cap 360 that is generally similar to the port cap 360a of FIGS. 14A-14F but also includes a loop hole 367 in the secondportion 364. The loop hole 367 can also allow the user to see a portionof the spike 164 so that the user is further prompted to remove the portcap 360 to access the spike 164. In the illustrated embodiment, the portcap 360 also includes a graphic, for example, a graphic of a persondisposing of trash in a bin. This can advantageously indicate to theuser that the port cap 360 is intended to be removed and discarded.

The port cap 360, 360 a, 360 b can be secured to the inlet 310 byfriction between the two components. In some embodiments, for example asshown in FIGS. 14G-14J, the first portion 362, 362 a, 362 b of the portcap 360, 360 a, 360 b can include an outer ring 370 configured to atleast partially encircle an outer perimeter of the inlet 310 and aninner ring 372 configured to at least partially encircle an innerperimeter of the inlet 310. In some embodiments, the port cap 360, 360a, 360 b is secured to the inlet 310 by friction between an innersurface of the inlet 310 and an outer surface of, for example, the innerring 372. In other embodiments, the port cap 360, 360 a, 360 b can besecured to the inlet 310 by friction between an inner surface of theouter ring 370 and an outer surface of the inlet 310. The first portion362, 362 a, 362 b further includes the float-restraining leg 374. Insome embodiments, the float-restraining leg 374 is formed integrallywith and/or is a continuation of the inner ring 372. For shipping andstorage, the port cap 362, 362 a, 362 b is coupled to the chamber 304such that the leg 374 extends into the inlet 310 to engage a tab 152extending from the float 150.

In some embodiments, the first portion 362 b of the port cap 360 b ofFIGS. 14K-14P can include one or more tear strips 365, for example asshown in FIG. 14L. The first portion 362 b can include a second tearstrip 365 located on an opposite side of the first portion 362 b fromthe tear strip 365 shown in FIG. 14L. In use, the user pulls up on thesecond portion 364 b to begin removing the port cap 360 b. The forces onthe second portion 364 b cause the intermediate portion 363 to begin tolift, which in turn applies an upward force to the first portion 362 b.When the second portion 364 b has been lifted a sufficient amount and/ora sufficient amount of force has been applied to the second portion 364b and transferred through the intermediate portion 363 to the firstportion 362 b, the first portion 362 b begins to tear along the tearstrip(s) 365. The first portion 362 b therefore can open similar to aclamshell to allow the user to more easily remove the port cap 360 bfrom the inlet 310.

The feedset or liquid conduit 118 can be wound into a loopedconfiguration and secured with a label 218, for example as shown inFIGS. 4G and 4H and described in the accompanying disclosure herein. Theend of liquid conduit 118 secured to the liquid inlet 117 and the end ofthe liquid conduit 118 secured to the spike 164 can extend from thelooped portion in the same direction so that the label 218 can slide offof the liquid conduit 118 as the user is setting up the system.Alternatively, the ends of the liquid conduit 118 can extend from thelooped portion in opposite directions, and the user can release theliquid conduit 118 from the looped configuration by tearing the label218. In some embodiments, this can allow for easier and quicker set-upbecause removing the label 218 to release the liquid conduit 118 can beeasier and quicker than unwinding the liquid conduit 118 from a winder.

In some embodiments, the chamber 304 includes a handle 368 in lieu of orin addition to grips 168. In some embodiments having an elbow shapedoutlet 312, a conduit or conduit connector coupled to the outlet 312will extend forward. This could make it more difficult for a user tograsp the grips 168. Therefore, the handle 368 can advantageouslyimprove access to the chamber 304 and make it easier for the user tograsp the chamber 304 when the conduit is connected to the outlet 312.The handle 368 and/or grips 168 can advantageously allow the user tograsp the chamber 304 more easily during installation and/or removal ofthe chamber 304 from the base 302. The handle 368 and/or grips 168 canalso allow the user to apply the force required to remove the chamber304 from the base 302 more easily. The handle 368 and/or grips 168 arevisually intuitive such that a user will typically understand thefunction of these features without requiring specific instructions. Thehandle 368 can also act as a brace, support, or pocket for the liquidconduit 118 during shipping and storage. For example, the handle 368 canprovide a partially enclosed capture area and/or shelf 369 (shown inFIG. 141) for the liquid conduit 118 during shipping and storage.

With reference now to FIG. 25, a further chamber assembly 600 isillustrated. The chamber assembly can include a chamber 602 thatincludes an inlet port 604 and an outlet port 606. In the illustratedconfiguration, the inlet port 604 extends generally vertically while theoutlet port 606 extends generally horizontally or at some angle otherthan generally vertically. The chamber 602 also includes a handle 608. Ashelf 610 can extend between a portion of the handle 608 and the body ofthe chamber 602. In some configurations, the shelf 610 may not beattached to one of the body of the chamber 602 and the handle 608. Thechamber assembly 600 also includes a water fill port 612. In someconfigurations, the water fill port 612 is positioned between the handle608 and the ports 604, 606. Other configurations are possible. Thechamber assembly 600 can have any suitable configuration. In someconfigurations, components illustrated in FIG. 25 may be omitted, or maybe removed and replaced by components from any of the above-describedembodiments, or the like.

In the illustrated configuration, a port cap 614 covers the inlet port604 during shipping and storage, for example. FIG. 31 illustrates avaried industrial design for the port cap 614. With reference to FIG.26, the port cap 614 can be a two piece configuration. The port cap 614can include a collar 616 and a post 618. The collar 616 and the post 618can be separable. The collar 616 can have a port encircling support 620.The support 620 can have any suitable configuration. In someconfigurations, the support 620 is a generally planar surface thatincludes an opening that is sized and configured to receive the inletport 604.

A retainer 622 can extend upwardly from the support 620. The retainer622 can define a forward-facing opening. In some configurations, theretainer 622 can be formed by a rectangular frame that is positionedgenerally forward of the inlet port 604. The retainer 622 and thesupport 620 can be integrally formed in some configurations.

The post 618 can be inserted into the inlet port 604. The post 618 caninclude a lid 626. The lid 626 can overlie at least a portion of theinlet port 604. The lid 626 can overlie at least a portion of the collar616. In some configurations, the lid 626 can overlie the entire collar616. In some configurations, the lid 626 can include a downwardlyextending flange 628. The flange 628 can generally enshroud three sidesof the collar 616. In some configurations, the flange 628 is slightlyspaced from the retainer 622.

With reference to FIG. 28, the post 618 of the port cap 614 also caninclude a finger 630. The finger 630 can be integrally formed with thelid 626. The finger 630 is configured to be received inside of thechamber 602. The chamber 602 can include one or more float 632, 634. Thefloats 632, 634 control operation of a valve that, in turn, controlsadmission of fluid into the chamber 602 through the water deliveryconduit 624. Further description of the float system can be found inU.S. Provisional Application No. 61/873,777, filed on Sep. 4, 2013 andU.S. Provisional Application No. 61/870,156, filed on Aug. 26, 2013,each of which is hereby incorporated by reference in its entirety.

With reference to FIG. 29, the inlet port 604 of the chamber 602 caninclude one or more internal structures 636. The one or more internalstructures 636 can be used to address flow or splashing within the flowpassing through the inlet port 604. In the illustrated configuration,the one or more internal structures 636 can be a baffle. The baffle 636extends at least partially below the inlet port 604.

The finger 630 is configured to extend through the inlet port 604 andbeyond the one or more internal structures 636. The finger 630 can havea portion above the structures 636 and a portion below the internalstructures 636. The finger 630 can be connected to the lid 626 at alocation generally vertically higher than the internal structures 636and the finger 630 can contact at least one of the floats 632, 634 at aposition vertically lower than the internal structures 636.

In the illustrated configuration, the finger 630 can include a firstcontact structure 640 and a second contact structure 642. The firstcontact structure 640 can be positioned between the second contactstructure 642 and the lid 626. The first contact structure 640 cancontact the primary float 634 while the second contact surface 642 cancontact the secondary float 632. The secondary float 632 can include thecontrol tab 638 and the second contact surface 642 can contact thecontrol tab 638. A similar configuration also can be used with theprimary float 634 and the first contact structure 640.

As shown in FIG. 27, a water delivery conduit 624 can be wrapped aboutthe inlet port 604. The wrapped water delivery conduit 624 can beinserted into the port cap 614 through the forward facing openingdefined by the retainer 622. The wrapped water delivery conduit 624 canbe positioned such that the inlet port 604 extends through the loop withthe support 620 underlying the loop. The post 618 can be inserted intothe port 604 with the finger 630 extending beyond the baffle 636. Thefinger 630 can hold the secondary float 632 and the primary float 634 insuch a position that the valve that controls the flow of water into thechamber is open. The finger 630 can be secured in position by frictionforces between the post 618 and the inlet port 604. The lid 626 and theflange 628 generally enclose the wrapped water delivery conduit 624. Asshown in FIG. 27, a spike 644 can be connected to the water deliveryconduit 624. The spike 644 can be housed between the handle 608 and thechamber 602. Tn some configurations, the spike 644 can be supported bythe shelf 610 that is positioned within at least a portion of a gapdefined between the handle 608.

With reference now to FIG. 30, during insertion of the chamber 602 intothe heater base, at least a portion of the port cap 614 can be liftedfrom the chamber 602. In the illustrated configuration, the heater basecan include a lifting surface 650. The lifting surface 650 can contact acontact surface 652 of the port cap 614 during insertion of the chamber602 into the heater base. In some configurations, the contact surface652 is a portion of the post 618. In some configurations, the contactsurface 652 is a portion of the flange 628. In some configurations, thecontact surface 652 is a lower edge of the flange 628. In someconfigurations, the contact surface 652 is a portion of the collar 616.In some configurations, the contact surface 652 is a lower surface ofthe collar 616.

As the chamber 602 is docked into position, the lifting of the post 618releases the floats 632, 634. In addition, the lifting of the post 618reveals the coiled fluid delivery conduit 624. In addition, because thepost 618 includes the finger 630 and because the coiled delivery conduit624 wraps around the finger 630, removal of the finger 630 enablesremoval of the conduit 624. For at least these reasons, the connectionof the spike 644 to a fluid source prior to releasing of the floats 632,634 is unlikely. Thus, overfilling of the chamber 602 is less likelywith the illustrated port cap 614.

With reference to FIGS. 32-37, an additional chamber assembly 700 isillustrated. The chamber assembly can include a chamber 702 thatincludes an inlet port 704 and an outlet port 706. In the illustratedconfiguration, the inlet port 704 extends generally vertically while theoutlet port 706 extends generally horizontally or at some angle otherthan generally vertically. The chamber 702 also includes a handle 708. Ashelf 710 can extend between a portion of the handle 708 and the body ofthe chamber 702. In some configurations, the shelf 710 may not beattached to one of the body of the chamber 702 and the handle 708. Thechamber assembly 700 also includes a water fill port 712. In someconfigurations, the water fill port 712 is positioned between the handle708 and the ports 704, 706. Other configurations are possible. Thechamber assembly 700 can have any suitable configuration. In someconfigurations, components illustrated in FIG. 32 may be omitted, or maybe removed and replaced by components from any of the above-describedembodiments, or the like. For example, although the example embodimentof FIG. 32 includes a handle 708 and shelf 710, the chamber assembly 700need not include the handle 708 or shelf 710.

In the illustrated configuration, a port cap 14 covers the inlet port704 during shipping and storage, for example. With reference to FIGS.35-37, the port cap 714 can be a two piece configuration. The port cap714 can include a collar 716 and a post 718. The collar 716 and the post718 can be separable. The collar 716 can have a port encircling support720. The support 720 can have any suitable configuration. In someconfigurations, the support 720 is a generally planar surface thatincludes an opening that is sized and configured to receive the inletport 704.

A retainer 722 can extend upwardly from the support 720. The retainer722 can define a forward-facing opening. In some configurations, theretainer 722 can be formed by a rectangular frame that is positionedgenerally forward of the opening for the inlet port 704. The retainer722 and the support 720 can be integrally formed in some configurations.

The post 718 can be inserted into the inlet port 704. The post 718 caninclude a lid 726. The lid 726 can overlie at least a portion of theinlet port 704. The lid 726 can overlie at least a portion of the collar716. In some configurations, the lid 726 can overlie the entire collar716. In some configurations, the lid 726 can include a downwardlyextending flange 728. The flange 728 can generally enshroud three sidesof the collar 716. In some configurations, the flange 728 is slightlyspaced from the retainer 722.

With reference to FIG. 35, the post 718 of the port cap 714 also caninclude a finger 730. The finger 730 can be integrally formed with thelid 726. The finger 730 is configured to be received inside of thechamber 702 and can be used to secure one or more floats in position ina similar manner to or the same as that described above.

As shown in FIG. 32, a water delivery conduit 724 can be wrapped aboutthe inlet port 704. The wrapped water delivery conduit 724 can beinserted into the port cap 714 through the forward facing openingdefined by the retainer 722. The wrapped water delivery conduit 724 canbe positioned such that the inlet port 704 extends through the loop withthe support 720 underlying the loop. The post 718 can be inserted intothe port 704 with the finger 730 extending into the chamber 702.

The lid 726 and the flange 728 generally enclose the wrapped waterdelivery conduit 724. As shown in FIG. 32, a spike 744 can be connectedto the water delivery conduit 724. The spike 744 can be received withina sleeve 745. In some configurations, the sleeve 745 is connected to theport cap 714. In some configurations, the sleeve 745 is connected to atleast one of the collar 716 and the post 714. In the illustratedconfiguration, the sleeve 745 is connected to the collar 716. The sleeve745 can be connected to the collar 716 in any suitable manner. Thesleeve 745 can be joined to the retainer 722. In some configurations,the sleeve 745 can be integrally formed with the retainer 722. In someconfigurations, the sleeve 745 can be formed separate of the retainer722 and secured thereto in any suitable manner. In the illustratedconfiguration, the sleeve is pivotally connected to the collar 716. Inthe some configurations, the sleeve 745 is pivotally connected to theretainer 722. In some such configurations, the sleeve 745 has a flange747 that is connected to the retainer 722. In some such configurations,the flange 747 extends upward from an edge of the retainer 722. In suchconfigurations, the sleeve 745 can pivot downwardly when then spike 744is positioned within the sleeve 745.

With reference now to FIGS. 32 and 35, the port cap 614 can include alifting structure 748. In some configurations, the lifting structure 748can be joined to any suitable surface of the port cap 614. In theillustrated configuration, the lifting structure is joined to the lid726. In some configurations, the lifting structure is joined to thefront of the lid 726. In some configurations, the lifting structure 748is pivotable relative to the port cap 614. The lifting structure 748 canhave any suitable configuration. In the illustrated configuration, thelifting structure 748 is a ring. In some configurations, the liftingstructure 748 can be a tab, hook or any other suitable structure. Thelifting structure serves as a visual indicator to help encourage removalof the port cap 614 while also facilitating the removal.

The heater base 302 can include a sensor cartridge module 400 similar tosensor cartridge module 200. Similar to chamber 104 and sensor cartridgemodule 200, chamber 304 and sensor cartridge module 400 can includelead-in features to help guide the operator through installation of thechamber 304 on the heater base 302 and help prevent or inhibit improperset up. For example, as shown in FIGS. 12 and 15, the sensor cartridgemodule 400 can include a central male projection 402 configured to slideinto a female recess 404 in the chamber 304 as shown in FIGS. 13A-13B.As shown, the recess 404 extends forward past a midpoint of or greaterthan halfway across the chamber 304, and the male projection 402 of thesensor cartridge module 400 extends past the midpoint of or greater thanhalfway across the chamber 304 when the chamber 304 is installed on thebase 302. In some embodiments, this causes the male projection 402 toengage the chamber 304 before the chamber 304 otherwise engages the base302, which can advantageously help guide the user in orienting thechamber 304 correctly on the base 302. For example, this feature canprevent or inhibit the user from attempting to install the chamber 304by placing the protruding portion 305 above or on top of the rim edge106. When the chamber 304 is properly installed, the top of the maleprojection 402 of the sensor cartridge module 400 and the top of thefront of the chamber 304 can form an at least substantially continuousor consistent slope. This can advantageously provide a visual cue to theuser that the chamber 304 has been properly installed.

In the illustrated embodiment, the sensor cartridge module 400 alsoincludes a central channel 410 along a lower surface of the central maleprojection 402. The central channel 410 is configured to receive acentral boss or raised portion 412 on the chamber 304. As shown, sidewalls of the central channel 410 can include generally horizontalgrooves 414. The grooves 414 can be configured to receive correspondingrails 416 extending along the sides of the raised portion 412 of thechamber 304, as shown in FIG. 13B. When the chamber 304 is installed onthe base 302 and coupled to the cartridge 400, the rails 416 sit in thegrooves 414. The coupling configuration of the rails 416 in the grooves414 can help inhibit the chamber 304 from excessive tilting.

The configuration and arrangement of, for example, the female recess 404and raised portion 412 on the chamber 304 make the front and rear of thechamber 304 highly asymmetric. This asymmetry, the configuration of thesensor cartridge 400, and/or the corresponding lead-in features on thechamber 304 and sensor cartridge 400 advantageously prevent or inhibitthe user from inserting the chamber 304 on the base 302 backwards orotherwise incorrectly setting up or misaligning the chamber 304 and/orbase 302. The raised portion 412 also provides a visual guide as to theproper orientation of the chamber 304 for insertion on the base 302.

In some embodiments, one or more of the components of the breathingcircuit assembly can be packaged for shipping and/or storage with an endcap 500 coupled to one or both ends of the conduit. An exampleembodiment of an end cap is shown in FIGS. 16-17. For example, an endcap 500 can be included on the end of Y-piece 127 as shown in FIGS. 18and 19. The end cap 500 includes a body 502 configured to be insertedinto the Y-piece, a flange 504, and a hook or pull ring 506.

The body 502 comprises frustoconical tapers 508. The tapers 508 promotea friction fit between the end cap 500 and Y-piece. The tapers 508 alsocreate a seal with the Y-piece. The illustrated embodiment includesthree tapers 508, although more or fewer are also possible. Multipletapers 508 provide redundancy to help ensure a sufficient seal andfriction fit. However, too many tapers 508 can create too great of acontact area. This can make the end cap 500 difficult to remove. In someembodiments, the body 502 can be sized to fit different sized Y-pieces,for example, both adult and infant Y-pieces.

The flange 504 is located on the end of the end cap 500 facing the basesor widest parts of the tapers 508. As shown, the flange 504 has ahexagonal shape. The hexagonal shape helps seal the end of the Y-pieceand aids end cap 500 removal. A width or diameter of the flange 504 isgreater than an outer diameter of the Y-piece to create an overhang. Forexample, for a 22 mm diameter Y-piece, the flange 504 can have a widthof about 24 mm. The hexagonal shape can also provide a visual indicatorthat the Y-piece connector is blocked and further inhibits the user fromattempting to attach other components while the end cap 500 is in place,which may be more likely if the flange 504 was round. Other non-circularshapes also can be used.

The hook 506 extends from the flange 504. The hook 506 advantageouslyallows the user to more easily grasp and remove the end cap 500 whenneeded. The hook 506 also allows the circuit to hang on a medical stand520 when not in use and/or during system set up, as shown in FIGS. 18and 19. The hook 506 can have a diameter of at least 8 mm to allow thehook 506 to accommodate medical stand hooks 522.

The body 502, flange 504, and hook 506 can be integrally formed ormolded to create a single-piece end cap 500. The end cap 500 should bemade of a material that is sufficiently strong while remaining soft orpliant enough to inhibit damage to the Y-piece. In some embodiments, theend cap 500 can be made of Thermolast K. In other embodiments, the endcap 500 can be made of Santoprene having a Shore A hardness of betweenabout 20 and 80, for example, about 55. Santoprene has a higher frictioncoefficient than some alternative materials, which can help improve endcap 500 retention in the Y-piece.

Alternative embodiments of end caps 500 are illustrated in FIGS.20A-24E. In these embodiments, the flange 504 is circular rather thanhexagonal. Additionally, as shown, the hook or pull ring 506 extendsfrom a side of the flange 504 rather than a top of the flange 504. Insome configurations, the hook can be a tab with an aperture definedthrough the tab. In any event, in the illustrated configurations, theaperture or hook can be positioned off to one lateral side of an axisextending through the body that engages with the component to which thecap is mounted. In other words, the aperture or hook is positioned offto one side of the body and/or flange. Locating the hook 506 to the sideof the flange 504 can cause the force used to remove the end cap 500 tobe applied in a rotational direction rather than a linear direction.This arrangement can advantageously allow the end cap 500 to be removedwith less force.

The hook 506 and flange 504 can have varying dimensions. For example,the embodiment of FIGS. 21A and 21B has a larger diameter hook 506 andlarger diameter flange 504 than the embodiment of FIGS. 20A and 20B. Ifthe end cap 500 of FIGS. 20A and 20B is connected to a Y-piece 127having an inner shell 124 a and an outer shell 124 b, the flange 504covers only the inner shell 124 a as shown in FIG. 20B. The flange 504of the end cap 500 of FIGS. 21A and 21B covers both the inner shell 124a and the outer shell 124 b as shown in FIG. 21B. FIGS. 22A and 23Aillustrate additional embodiments of end caps 500, and FIGS. 22B and 23Billustrate the end caps of FIGS. 22A and 23A, respectively, coupled to aY-piece 127. FIGS. 24A-24E illustrate the end caps of FIGS. 16, 20A,21A, 22A, and 23A, respectively, coupled to an alternative Y-piece 227.The Y-piece 227 of FIGS. 24A-24E can be used for an infant patient.

FIG. 38 illustrates a system comprising a chamber 25, a circuit 50 and acap 800. The chamber 25 is configured to hold a liquid, such as, forexample, water. The chamber 25 is configured to couple with a heatingapparatus that, in use, heats the liquid and, thereby, forms vapour. Thechamber is configured to couple with a gases source such that gasesprovided to the chamber are heated and take up the vapour as they travelthrough the chamber. The heated, humidified gases are delivered by thecircuit 50 to the patient. The cap 800 is configured to be attached tothe circuit 50. The illustrated circuit 50 is an example of a circuit towhich the cap 800 can be attached and is not meant to be limiting. In anembodiment, the cap 800 is configured to couple with an intermediaterespiratory component, such as, for example, a wye-piece, or anadditional circuit.

Sealing, as herein described, refers to at least partial sealing of amedical component, such as, for example, a circuit. Sealing prevents, orat least partially prevents, dust, or larger contaminants, such as afinger, for example, from entering the circuit. Sealing could beachieved by the use of a tortuous path, a cap, or a cap that provides atortuous path. The tortuous path substantially seals or at leastpartially seals the circuit (i.e., may not result in a completely airimpervious seal).

FIGS. 39A-39D illustrate the cap 800 in more detail. The cap 800comprises a ring 801 connected to a plug 804. The ring 801 may beconnected to the plug 804 by a throat 802. The plug 804 comprises a disc814 and a body 805. The disc 814 comprises an upper surface 816 and alower surface 818. The disc 814 has a diameter that is larger than thediameter of the body 805. The disc 814 further comprises a lip 808 thatextends from the lower surface 818. The plug 804 comprises a roughlycylindrical structure defining a tube. The tube comprises a first endand a second end. The first end is sealed by the lower surface 818 ofthe disc 814. The second end is branched by a pair of ribs 812 that areperpendicular to each other. The ribs 812 are coupled with the lowersurface 818 and abut an internal wall of the body 805. The plug 804comprises four segments of three frustoconical tapers 806 adjacent tothe body 805. Each of a plurality of channels 810 is defined betweenadjacent segments of the frustoconical tapers 806. The plurality ofchannels 810 extend into the lower surface 818.

The ring 801 has a diameter large enough to insert a finger. Forexample, the diameter may be greater than 8 mm. In the illustratedembodiment, the diameter is 25 mm. The ring 801 is configured to enableeasy removal of the cap 800 from the circuit 50. The ring 801 isconfigured to allow the cap 800 to be removed from the circuit 50without use of excessive force while the retaining force created byfriction between the body 805 and the circuit 50 remains enough to holdthe cap 800 in place when the circuit 50 is hung. In an embodiment, thecap 800 is configured to be removed by a force in the range of 5-30Newtons (N). In an embodiment, the cap 800 is configured to be removedby a force in the range of 5-15 N. In an embodiment, the cap 800 isconfigured to be removed by a force of about 15 N. This provides aretention force that is strong enough to support the weight of thecircuit 50 and yet allows a user to insert and remove the cap 800without impacting the usability of the circuit 50.

The ring 801 enables the circuit 50 to be hung on a supportingstructure, such as a medical stand or hook, for example. Thisfacilitates easy storage of the circuit 50 prior to use, during a pausein use, or following use. The system can be set up prior to use and beready for use by a patient.

The plug 804 is coupled with the ring 801 by the throat 802. This causesleverage to be applied to the plug 804 when a force is applied to thering 801, which reduces the force required to remove the cap 800 fromthe circuit 50. The length of the throat 802 can be increased toincrease the amount of leverage applied to the plug 804. In theillustrated embodiment, the length of the throat 802 is 3 mm. The widthof the throat 802 can also be increased to increase the amount ofleverage applied to the plug 804. In an embodiment, the ring 801 isdirectly coupled to the plug 804 with no intervening throat. Thisreduces the overall size of the cap 800 but increases the force requiredto remove the cap 800 from the circuit 50.

The body 805 of the plug 804 couples with the circuit 50. In theillustrated embodiment, the body 805 is configured to be a malecomponent. Thus, the body 805 is received by the circuit 50 and extendsinto the interior of the circuit 50. The body 805 is configured to beheld in place in the circuit 50 by, for example, a friction fit. In theillustrated embodiment, the body 805 is configured to fit a 22 mm tapercircuit connector. A male component renders the cap 800 independent ofthe external configuration of the circuit connector. Thus, the cap 800can be used with different circuits having the same internal connectorsize, for example, a 22 mm taper.

In an embodiment, the body 805 comprises a female component that isconfigured to receive the circuit 50. This protects the interior of thecircuit from potential damage due to interaction with the body 805.

The size of the cap 800, or the plug 804, can be scaled to fit, forexample, 8.5 mm, 12 mm, 15 mm, 17 mm, 22 mm, 23 mm, or 30 mm tapers.This enables the cap 800 to be used with a variety of medicalcomponents, such as, but not limited to, a wye-piece, medical circuitsor interface circuits of different sizes.

The body 805 comprises four segmented groups, each comprising threefrustoconical tapers 806. The groups of frustoconical tapers 806 areconfigured to form a sealing interface with the interior of the circuit50. The sealing interface is formed using a friction fit between thefrustoconical tapers 806 and the interior of the circuit 50. Thefrustoconical tapers 806 hold the cap 800 in place in the circuit 50during use until sufficient force is applied to remove the cap 800 fromthe circuit. Three frustoconical tapers 806 are chosen such that theforce required to remove the cap 800 from the circuit 50 is within thecapabilities of a user and yet exceeds other forces encountered duringuse.

In an embodiment, a single frustoconical taper 806, or two frustoconicaltapers 806, form the sealing interface with the interior of the circuit50. The single or two frustoconical tapers 806 reduce the length of thebody 805 that is inserted into the interior of the circuit 50 whilefacilitating sealing between the body 805 and the interior of thecircuit. The single or two frustoconical tapers 806 reduce the forcerequired to remove the cap 800 from the circuit 50.

In a further embodiment, four or more frustoconical tapers 806 form thesealing interface with the interior of the circuit 50. Four or morefrustoconical tapers 806 improve the sealing between the body 805 andthe interior of the circuit 50.

The segmented groups of frustoconical tapers 806 are each separated bythe channels 810. The channels 810 form a path through which gaseswithin the circuit 50 can move into the atmosphere. Thus, the channels810 provide a way for the gases to vent from the circuit 50 should auser initiate gases flow through the circuit while the cap 800 is inplace. The channels 810 are located on the body 805 and, thus, arereceived by the circuit 50 as the body 805 is inserted into the circuit.The channels 810 are subtle and do not negatively impact the overalllook of the cap 800. As illustrated in FIG. 39B, the width (w) of eachof the channels 810 is 5 mm. In the illustrated embodiment, the depth(d) of each of the channels 810 at the deepest point is 1.3 mm. Thedepth (d) of each of the channels 810 can be varied provided it remainswithin manufacturing constraints, for example, greater than 1 mm. A thinmaterial is vulnerable to breakage and a thick material takes time tocool, which can lead to distortion of the parts.

In an embodiment, the width of the channels 810 is less than 5 mm, forexample, 2 mm. This improves the sealing between the cap 800 and thecircuit 50. In a further embodiment, the width of the channels 810 isgreater than 5 mm, for example, 7 mm. This improves the venting capacityof the cap 800.

The four channels 810 may be spaced evenly around the perimeter of thebody 805. This reduces the likelihood of the cap becoming unsealed anddisconnecting with the circuit 50 due to an uneven amount of gases beingvented to the atmosphere through each channel. Four channels 810 canwithstand expected pressures at typical operating pressures, such as 13kPa at 60 lpm or 20 kPa at 70 lpm.

In an embodiment, two channels 810, substantially evenly spaced aroundthe perimeter of the body 805 maintain a high sealing force between thecap 800 and the circuit 50.

In an embodiment, three channels 810 substantially evenly spaced aroundthe perimeter of the body 805 allow more venting to the atmosphere.

In an embodiment, five channels 810 substantially evenly spaced aroundthe perimeter of the body 805 increase the venting of gases to theatmosphere. Thus, more venting of gases to the atmosphere can occur witha larger number of the channels 810.

The illustrated embodiment optimises the sealing force with the ventingcapacity of the cap 800. For example, 27% of the sealing diameter of thecap 800 facilitates venting gases to the atmosphere and 73% of thesealing diameter of the cap 800 forms sealing surfaces between the cap800 and the circuit. A greater venting capacity may negatively impactthe sealing of the cap 800, which may cause the cap 800 to come off inuse. Greater sealing of the cap 800 may reduce the venting capacity,which may cause the cap 800 to come off in use. Evenly spaced orsubstantially evenly spaced channels 810 around the perimeter of thebody 805 provides more balanced venting of the gases to the atmosphere.This reduces the chance of the cap 800 coming off upon activation of thegases source.

The channels 810 extend into the lower surface 818 of the disc 814. Thisfacilitates venting of gases from within the interior of the circuit 50to the atmosphere by preventing the lower surface 818 or the disc 814from sealing onto the circuit connector, such as might be encountered,for example, if the circuit 50 is coupled to the cap 800 such that theconnector is flush with the lower surface 818. The channels 810 protrudeby 0.5 mm into the lower surface 818 of the disc 814.

In an embodiment, the channels 810 extend into the lip 808 of the disc814 to further facilitate venting of gases from within the interior ofthe circuit 50 to the atmosphere. The channels 810 protrude into the lip808 of the disc 814 by 0.5 mm.

A pair of ribs 812, which are perpendicular to each other, branch thediameter of the second end of the tube formed by the body 805. The ribs812 provide structural support to the body 805. This enables the body805 to be received by the interior of the circuit 50 forming a seal.

In an embodiment, multiple ribs 812 provide additional structuralsupport to the body 805.

In a further embodiment, a single rib 812 is used to provide structuralsupport to the body 805. This reduces the amount of material required toform the cap 800 and simplifies the structure of the cap 800.

The disc 814 forms a barrier that at least partially seals the circuit50 from the atmosphere. For example, the disc 814 prevents dust andlarger contaminants, such as a finger or a medical instrument, frombeing inserted into the circuit 50 while it is attached to the cap 800.The disc 814 indicates to the user that the cap 800 should be removedprior to attaching a medical component to the circuit 50. For example,the disc 814 comprises a diameter that is larger than the diameter ofthe circuit. In the illustrated embodiment, the diameter of the disc 814comprises 30 mm, compared with the circuit diameter of 22 mm.

In an alternative embodiment, the disc 814 comprises an eye-catchingshape, for example, a hexagon or a square, to encourage the user toremove the cap 800 prior to use of the circuit 50.

In the illustrated embodiment, the upper surface 816 of the disc 814comprises a visual indicator, by way of a drawing, colour, message orinstructions to the user. The visual indicator indicates to the user,for example, correct usage of the cap 800 or disposal of the cap 800.The visual indicator can be embossed, raised or printed onto the uppersurface 816.

In an embodiment, the upper surface 816 is colour coordinated with othermedical components in the system. In an alternative embodiment, theupper surface 816 comprises a colour that indicates the cap 800 isdisposable, such as, for example, red.

The lower surface 818 of the disc 814 seals the first end of the tube asdefined by the body 805. The lip 808 surrounds the lower surface 818 ofthe disc 814. The lip 808 improves the aesthetic features of the cap800, such as, for example, by subtly incorporating the channels 810 intothe cap 800. In the illustrated embodiment, the lip 808 is 1.5 mm high.The lip 808 improves the sealing between the cap 800 and the circuit bysealing onto the exterior of the circuit.

The cap 800 is made from a material that does not damage the interior ofthe circuit when a friction fit is formed between the cap 800 and theinterior of the circuit. The material is soft to protect the circuit andyet sufficiently rigid that the structure of the cap 800 is maintained.An example of an appropriate material is a thermoplastic elastomer, athermoplastic polyurethane, or an elastomer.

FIG. 40 illustrates an example embodiment, wherein a cap 900 comprises aplug 904. The plug 904 comprises a body 905 that is configured to bereceived by the circuit 50. The body 905 comprises segmented groups offrustoconical tapers 906 configured to at least partially seal with theinterior of the circuit. The segmented groups of frustoconical tapers906 are each separated by the channels 910. The channels 910 form apathway through which gases within the circuit can vent to theatmosphere if a gases source is activated prior to removal of the cap900 from the circuit.

The channels 910 comprise at least one orifice 920 to facilitate ventingof gases from the circuit to the atmosphere. The at least one orifice920 extend through the channels 910 and are configured to form a pathwaybetween the lumen of the circuit 50 and the atmosphere. The channels 910help to direct the vented gases toward the at least one orifice 920. Inthe illustrated embodiment, the channels 910 comprise two orifices 920.The orifices 920 can be used in combination with the channels 910 tofurther facilitate venting of the gases from the circuit to theatmosphere. In the illustrated embodiment, the orifices 920 are shownpositioned near a lower surface 918 of a disc 914. Thus, the orifices920 are positioned open to the atmosphere and are not sealed by theinterior of the circuit. As a result, the cap 900 has a greater capacityto vent gases to the atmosphere.

In an embodiment, the cap 900 comprises multiple orifices 920. Forexample, the cap 900 may comprise three or more orifices 920, whichfurther facilitate the venting of gases from the circuit.

In a further embodiment, the cap 900 comprises at least one orifice 920with a larger diameter. This increases the capacity of the cap 900 tovent gases from the circuit 50. As a result, a reduced number of theorifices 920 is used while facilitating additional venting of gases fromthe circuit. Alternatively, the orifices 920 comprise a smallerdiameter. This renders the orifices 920 more subtle and less obtrusiveto the user. A smaller diameter also reduces the likelihood of dust orother contaminants entering the circuit. Thus, multiple orifices 920 areused to allow additional venting from the circuit.

In a further embodiment, the orifices 920 are positioned on at least oneof the frustoconical tapers 906. The orifices 920 can be used without orinstead of the channels 910. In this embodiment, the sealing surfaces ofthe cap 900 are increased, facilitating better sealing between the cap900 and the circuit.

In a further embodiment, the orifices 920 are positioned within theportions of the channels 910 that extend into the lower surface 918 ofthe disc 914. The orifices 920 thus protrude through the upper surface916 of the disc 914. Thus, the channels 910 direct the gases toward boththe atmosphere and the orifices 920. This facilitates greater venting ofthe gases without negatively impacting the sealing forces of the cap900.

FIGS. 41A and 41B illustrate an example embodiment, wherein a cap 1000comprises a plug 1004, a disc 1014 comprising an upper surface 1016 anda lower surface 1018, a pair of ribs 1012 that are perpendicular to eachother, and at least one cut-out 1020. The cut-out 1020 comprises apassageway through at least a portion of the disc 1014 to facilitateventing through the cut-out 1020. In the illustrated embodiment, twocut-outs 1020 traverse through the lower surface 1018 and the uppersurface 1016 of the disc. This enables the gases within the circuit tobe vented to the atmosphere. The cut-outs 1020 are positioned oppositeeach other and near the ribs 1012. The ribs 1012 may provide anindication as to the position of the cut-outs 1020. For example, thecut-outs 1020 can be positioned in a vertex that is defined by the ribs.Portions of the cut-outs 1020 may protrude from the upper surface 1016of the disc 1014 as gases are vented to the atmosphere. The cut-outs1020 give the cap 1000 the capacity to vent gases to the atmospherewhile increasing or maximising the sealing that occurs between the cap1000 and the circuit.

In the illustrated embodiment, the cut-out 1020 is illustrated as a pairof lines forming a right angle. However, in some embodiments, thecut-out 1020 comprises a slit, an orifice (for example, the orifice 920illustrated in FIG. 40), or any other appropriate form of opening.

In an embodiment, multiple cut-outs 1020, for example, four cut-outs1020, are used to facilitate venting of the gases from the circuit. Thefour cut-outs 1020 are positioned at each of the vertices formed by theribs 1012.

In a further embodiment, the disc 1014 comprises the at least onecut-out 1020, for example, around the perimeter of the disc 1014. The atleast one cut-out 1020 is subtly incorporated into the disc 1014. Forexample, the at least one cut-out 1020 is incorporated into a pattern,message, or drawing that appears on the upper surface 1016 of the disc1014.

FIGS. 42A and 42B illustrate an example embodiment, wherein a cap 1100comprises a plug 1104, a disc 1114 that further comprises an uppersurface 1116 and a lower surface 1118, a pair of ribs 1112 that areperpendicular to each other, and at least one orifice 1120. The at leastone orifice 1120 is configured to allow gases within the circuit to ventto the atmosphere via the disc 1114. Thus, the cap 1100 has capacity toallow venting of gases to the atmosphere while maintaining a maximumsealing force with the interior of the circuit.

In the illustrated embodiment, the cap 1100 comprises multiple orifices1120. The orifices 1120 extend through both the lower surface 1118 andthe upper surface 1116 of the disc 1114, thereby forming a passagewaythrough which gases can move. The upper surface 1116 comprises a loweredregion 1124 that is surrounded by a ledge 1122. In the illustratedembodiment, the ledge 1122 positions the lowered region 1124 2 mm belowthe upper surface 1116. The multiple orifices 1120 are positioned aroundthe perimeter of the lowered region 1124 near the ledge 1122. The ledge1122 extends at least partially over the multiple orifices 1120. Thisprovides a tortuous path for dust or other contaminants to enter thecircuit via the cap 1100. It also enables the multiple orifices 1120 tobe more subtly incorporated into the cap 1100.

In an embodiment, multiple orifices 1120 comprise a small diameter, forexample, between 1 mm and 5 mm. In the illustrated embodiment, themultiple orifices 1120 are 3.5 mm long (l) and 2.5 mm wide (w). Thisprovides a tortuous path for dust or other contaminants to enter the cap1100 and is more subtle to incorporate into the upper surface 1116 ofthe cap 1100.

In an embodiment, the orifices 1120 comprise a large diameter, forexample, 5 mm to 10 mm. Thus, less of the orifices 1120 are used toenable gases within the circuit to vent to the atmosphere. A largediameter improves the venting capacity of the cap 1100. Thus, the cap1100 is more likely to address what might otherwise be higher pressuresof gases within the circuit. In an embodiment, the orifices 1120 on theupper surface 1116 have a length (l) of 1 mm to 10 mm, and a height of 1mm, which extends from the lowered region 1124 into the ledge 1122.

In a further embodiment, the orifice 1120 comprises a slit or curvedrectangular shape. In an embodiment, a single orifice 1120 runs alongthe perimeter of the lowered region 1124. In an embodiment, multipleorifices 1120, for example, two, three, or more orifices 1120, extendaround the perimeter of the lowered region 1124. The orifices 1120comprise slits that allow venting of gases from the interior of thecircuit to the atmosphere.

FIGS. 43A and 43B illustrate an example embodiment, wherein a cap 1200comprises a ring 1201, a throat 1202 and a body 1204. The body 1204comprises an inner surface 1206, an outer surface 1214, a flange 1208and channels 1210. The ring 1201 and the throat 1202 function asdescribed in the above embodiments. The body 1204 is a female part and,thus, is configured to receive the circuit. The exterior of the circuitand the inner surface 1206 are configured to form a sealing surface. Thebody 1204 comprises the flange 1208 that forms an outer rim of the body1204. The flange 1208 is angled outwardly from the inner surface 1206 ofthe cap 1200. Channels 1210 are positioned adjacent to the flange 1208,between the flange 1208 and the inner surface 1206. The channels 1210are indentations formed on the inner surface 1206 of the body 1204 andare configured to direct a gases flow from the circuit to theatmosphere. Four such channels 1210 exist in the illustrated embodiment.

In use, the cap 1200 is configured to deform if a gases source isactivated. For example, pressure in the circuit causes the outer surface1214 of the cap 1200 to deform such that the position of the cap 1200relative to the circuit is altered. The cap 1200 moves nearer to the endof the circuit, while remaining coupled with the circuit. The innersurface 1206 of the body 1204 is no longer flush with the exterior ofthe circuit. This enables gases from within the circuit to vent to theatmosphere through the channels 1210.

In an embodiment, the channels 1210 comprise orifices that extendthrough the body 1204 of the cap 1200. This allows direct venting ofgases from the circuit to the atmosphere.

In a further embodiment, multiple channels 1210, for example, greaterthan four channels 1210, are used to direct gases to the atmosphere.This improves the venting capacity of the cap 1200.

In a further embodiment, the length of the channels 1210 is altered suchthat the channels 1210 extend into the flange 1208 of the cap 1200.Thus, less deformation of the cap 1200 is required to enable gases to bedirected to the atmosphere.

In a further embodiment, the flange 1208 further comprises a crimpededge 1209. The crimped edge 1209 is coupled with a channel 1210. Thus,the gases are directed by the channel 1210 to the crimped edge 1209where they are released to the atmosphere. Thus, the crimped edge 1209improves the efficiency by which gases are vented to the atmosphere. Thecrimped edge 1209 also creates a cap 1200 that is pleasing to the eye ofthe user. A single crimped edge 1209 is evident in the illustratedembodiment of FIG. 43A; however, multiple of the crimped edge 1209 couldbe used.

Although this disclosure has been described in the context of certainembodiments and examples, it will be understood by those skilled in theart that the disclosure extends beyond the specifically disclosedembodiments to other alternative embodiments and/or uses and obviousmodifications and equivalents thereof. While the description aboverefers to a “user,” it should be noted that the ultimate user can be apatient and the apparatus described herein can be assembled by a nurse,doctor or other healthcare practitioner in a clinical or healthcarerelated facility as well as a user/patient in a home use, for examplebut without limitation. In addition, while several variations of theembodiments of the disclosure have been shown and described in detail,other modifications, which are within the scope of this disclosure, willbe readily apparent to those of skill in the art. It is alsocontemplated that various combinations or sub-combinations of thespecific features and aspects of the embodiments may be made and stillfall within the scope of the disclosure. It should be understood thatvarious features and aspects of the disclosed embodiments can becombined with, or substituted for, one another in order to form varyingmodes of the embodiments of the disclosure. Furthermore, dimensions ofvarious components provided herein are exemplary, and other dimensionsmay be used. Thus, it is intended that the scope of the disclosureherein should not be limited by the particular embodiments describedabove.

What is claimed is:
 1. A humidification apparatus comprising: ahumidification chamber configured to hold a volume of liquid andcomprising: at least one side wall; a top wall connected to the at leastone side wall; a base surface connected to the at least one side wall; acavity at least partially defined by the at least one side wall and thetop wall; an inlet port defining a passage into the cavity of thehumidification chamber; an outlet port defining a passage out of thecavity of the humidification chamber and having an elbow configuration,wherein the outlet port is uncovered for shipping and/or storage; and aport cap configured to cover the inlet port for shipping and/or storage,the port cap comprising a leg that extends into the inlet port.
 2. Thehumidification apparatus of claim 1, wherein the inlet port comprises abaffle extending at least partially below the inlet port and configuredto inhibit splashing through the inlet port, and wherein the leg of theport cap is configured to extend beyond the baffle.
 3. Thehumidification apparatus of claim 1, wherein the leg is configured tosecure one or more floats within the humidification chamber for shippingand/or storage.
 4. The humidification apparatus of claim 1, furthercomprising a liquid inlet in fluid communication with the cavity and aliquid conduit having a first end coupled to the liquid inlet and asecond end coupled to a spike configured to be connected to a liquidsource, wherein the spike is positioned under the port cap for shippingand/or storage.
 5. The humidification apparatus of claim 4, wherein theliquid conduit is looped and inserted under the port cap during assemblyfor shipping and/or storage.
 6. The humidification apparatus of claim 1,further comprising a liquid inlet in fluid communication with the cavityand a liquid conduit having a first end coupled to the liquid inlet anda second end coupled to a spike configured to be connected to a liquidsource, wherein the spike is stored in a sheath attached to the port capfor shipping and/or storage.
 7. The humidification apparatus of claim 1,further comprising a handle coupled to the chamber, a shelf extendingbetween a portion of the handle and a portion of the at least one sidewall of the chamber, a liquid inlet in fluid communication with thecavity, and a liquid conduit having a first end coupled to the liquidinlet and a second end coupled to a spike configured to be connected toa liquid source, wherein the spike is stored on the shelf for shippingand/or storage.
 8. The humidification apparatus of claim 7, wherein theliquid conduit is stored on the shelf for shipping and/or storage. 9.The humidification apparatus of claim 1, wherein the port cap comprisesa ring configured to be grasped for removal of the port cap and to beattached to a medical stand.
 10. The humidification apparatus of claim1, further comprising an inspiratory conduit having a first end coupledto the outlet port for shipping and/or storage.
 11. The humidificationapparatus of claim 1, wherein the port cap comprises a contact surfaceand a heater base configured to support the humidification chambercomprises a lifting surface, wherein when the humidification chamber isinserted onto the heater base with the port cap covering the inlet port,the lifting surface contacts the contact surface and causes the port capto lift away from the inlet port.
 12. The humidification apparatus ofclaim 11, wherein the lifting surface is on a sensor cartridge modulecoupled to the heater base.
 13. A circuit end cap comprising: a bodyconfigured to be inserted into an end of a breathing circuit component;a flange at a first end of the body, wherein a diameter of the flange islarger than a diameter of the body and a lower surface of the flangefacing the body is configured to seal against the end of the breathingcircuit component; and a pull ring extending from the body andconfigured to be used to aid removal of the circuit end cap from thebreathing circuit component and/or to hang the breathing circuitcomponent from a medical stand or hook.
 14. The circuit end cap of claim13, wherein the body comprises frustoconical tapers configured to form asealing interface with an interior of the breathing circuit component.15. The circuit end cap of claim 14, wherein the body comprises threefrustoconical tapers such that the frustoconical tapers provide asufficient friction fit with the breathing circuit component whileallowing the circuit end cap to be removed from the breathing circuitcomponent without excessive force.
 16. The circuit end cap of claim 13,wherein the pull ring extends from a top surface of the flange along alongitudinal axis of the body.
 17. The circuit end cap of claim 13,wherein the pull ring extends from a side of the flange perpendicularlyto a longitudinal axis of the body.
 18. The circuit end cap of claim 13,wherein a diameter of the flange can be selected for use with variousbreathing circuit components.
 19. The circuit end cap of claim 14,wherein diameter of the body and frustoconical tapers can be selectedfor use with various breathing circuit components.
 20. The circuit endcap of claim 13, wherein the body comprises a plurality of channels,each channel extending parallel to a longitudinal axis of the body on anoutside surface of the body, wherein the channels allow gases to ventfrom the breathing circuit component.
 21. The circuit end cap of claim20, wherein the plurality of channels extend into the lower surface ofthe flange.
 22. The circuit end cap of claim 14, wherein the bodycomprises a plurality of channels extending parallel to a longitudinalaxis of the body on an outside surface of the body, wherein the channelsseparate the frustoconical tapers into a plurality of segments.